Process for making a pet food in the form of a coated kibble

ABSTRACT

A process of making a pet food include providing a core pellet; providing at least one coating material; applying the coating material to the core pellet to form a coated kibble using a continuous fluidizing mixer; wherein application of the coating material occurs at a Froude number range of from about 0.8 to about 3 and a Peclet number greater than about 6.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 13/009,872, filed on Jan.20, 2011 (Pending), which, in turn, claims the benefit of and priorityto U.S. Provisional Application No. 61/297,391, which was filed on Jan.22, 2010.

FIELD

The present invention relates to the field of processes for making a petfood. The present invention more particularly, but not exclusively,relates to coating a core with a coating material.

BACKGROUND

Pet food manufacturers continually try to improve dry pet foods to makethem more nutritious and taste better. Dry pet foods are typicallyextruded using heat and pressure to make nutritionally balanced, lowmoisture pellets (kibbles) that are shelf-stable. Unfortunately, thesedry kibbles can often be bland-tasting to the animal, so manufacturersusually coat the kibbles with a fat or a palatant to improve the flavor.However, it has now been found that if some of the ingredients normallyadded to the extruder are instead saved for after extrusion and coatedon the outside, the kibble can have improved flavor without adding asmuch extra fat or palatants. This coating on the outside after extrusionnot only saves costs but also results in less nutrition degradationsince these ingredients do not go through the extruder and thus do notexperience the heat and pressure thereof. Thus, the product is lessexpensive, better tasting, and higher in nutrition. For examplevitamins, Probiotics, or other temperature sensitive nutritionalingredients can be added to the surface of the kibble post-extrusionresulting in a higher level of active material on the kibble due to theless thermal degradation. It has also been found that when nutrientssuch as amino acids and animal proteins are added to the outside of thekibble, the kibbles taste better to the animals, and nutrients are oftenmore digestible. Accordingly, aspects of these benefits ofpost-extrusion processing are disclosed herein.

SUMMARY

In one embodiment, a process of making a pet food is disclosed. Theprocess can include providing a core pellet; providing at least onecoating material; applying the coating material to the core pellet toform a coated kibble using a continuous fluidizing mixer; whereinapplication of the coating material occurs at a Froude number range offrom about 0.8 to about 3 and a Peclet number greater than about 6. Inone embodiment, the process can result in an average residence time ofthe core pellet within the continuous fluidizing mixer to be from about10 seconds to about 600 seconds. In one embodiment, the continuousfluidizing mixer can utilize paddles in a rotation that iscounter-rotating. In one embodiment, the counter-rotating paddles cancause the core material to have an upwardly convective flow near thecenter of the continuous fluidizing mixer. In one embodiment, thecontinuous fluidizing mixer can be operated such that the core materialshave a flow through the continuous fluidizing mixer of from about 10kg/hr to about 60,000 kg/hr. In some embodiments, the coating materialcan include a Probiotic, mannoheptulose, and/or an emulsifier having aplurality of hydroxyl groups, such as polysorbate ester or polysorbate80.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts one embodiment of a kibble in the form of a coating on acore.

FIG. 2 shows a comparison of total aldehydes.

FIG. 3 shows a comparison of an oxygen bomb test.

FIG. 4 provides the results of an aroma characterization.

FIG. 5 provides the results of an aroma characterization.

FIG. 6 provides the results of an aroma characterization.

FIG. 7 provides the results of a vitamin loss comparison.

FIG. 8 provides the results of a vitamin loss comparison.

DETAILED DESCRIPTION Definitions

As used herein, the articles including “the”, “a”, and “an”, when usedin a claim or in the specification, are understood to mean one or moreof what is claimed or described.

As used herein, the terms “include”, “includes”, and “including” aremeant to be non-limiting.

As used herein, the term “plurality” means more than one.

As used herein, the term “kibble” includes a particulate pellet likecomponent of animal feeds, such as dog and cat feeds, typically having amoisture, or water, content of less than 12% by weight. Kibbles mayrange in texture from hard to soft. Kibbles may range in internalstructure from expanded to dense. Kibbles may be formed by an extrusionprocess. In non-limiting examples, a kibble can be formed from a coreand a coating to form a kibble that is coated, also called a coatedkibble. It should be understood that when the term “kibble” is used, itcan refer to an uncoated kibble or a coated kibble.

As used herein, the terms “animal” or “pet” mean a domestic animalincluding, but not limited to domestic dogs, cats, horses, cows,ferrets, rabbits, pigs, rats, mice, gerbils, hamsters, horses, and thelike. Domestic dogs and cats are particular examples of pets.

As used herein, the terms “animal feed”, “animal feed compositions”,“animal feed kibble”, “pet food”, or “pet food composition” all mean acomposition intended for ingestion by a pet. Pet foods may include,without limitation, nutritionally balanced compositions suitable fordaily feed, such as kibbles, as well as supplements and/or treats, whichmay or may not be nutritionally balanced.

As used herein, the term “nutritionally balanced” means that thecomposition, such as pet food, has known required nutrients to sustainlife in proper amounts and proportion based on recommendations ofrecognized authorities, including governmental agencies, such as, butnot limited to, Unites States Food and Drug Administration's Center forVeterinarian Medicine, the American Feed Control Officials Incorporated,in the field of pet nutrition, except for the additional need for water.

As used herein, the terms “Probiotic”, “Probiotic component”, “Probioticingredient”, or “Probiotic organism” mean bacteria or othermicroorganisms, either viable or dead, their constituents such asproteins or carbohydrates, or purified fractions of bacterial ferments,including those in the dormant state and spores, that are capable ofpromoting mammalian health by preserving and/or promoting the naturalmicroflora in the GI tract and reinforcing the normal controls onaberrant immune responses.

As used herein, the term “core”, or “core matrix”, means the particulatepellet of a kibble and is typically formed from a core matrix ofingredients and has a moisture, or water, content of less than 12% byweight. The particulate pellet may be coated to form a coating on acore, which may be a coated kibble. The core may be without a coating ormay be with a partial coating. In an embodiment without a coating, theparticulate pellet may comprise the entire kibble. Cores can comprisefarinaceous material, proteinaceous material, and mixtures andcombinations thereof. In one embodiment, the core can comprise a corematrix of protein, carbohydrate, and fat.

As used herein, the term “coating” means a partial or complete covering,typically on a core, that covers at least a portion of a surface, forexample a surface of a core. In one example, a core may be partiallycovered with a coating such that only part of the core is covered, andpart of the core is not covered and is thus exposed. In another example,the core may be completely covered with a coating such that the entirecore is covered and thus not exposed. Therefore, a coating may coverfrom a negligible amount up to the entire surface. A coating can also becoated onto other coatings such that a layering of coatings can bepresent. For example, a core can be completed coated with coating A, andcoating A can be completely coated with coating B, such that coating Aand coating B each form a layer.

As used herein, the term “macronutrient” means a source, or sources, ofprotein, fat, carbohydrate, and/or combinations and/or mixtures thereof.

As used herein, the term “extrude” means an animal feed that has beenprocessed by, such as by being sent through, an extruder. In oneembodiment of extrusion, kibbles are formed by an extrusion processeswherein raw materials, including starch, can be extruded under heat andpressure to gelatinize the starch and to form the pelletized kibbleform, which can be a core. Any type of extruder can be used,non-limiting examples of which include single screw extruders andtwin-screw extruders.

The list of sources, ingredients, and components as describedhereinafter are listed such that combinations and mixtures thereof arealso contemplated and within the scope herein.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

All lists of items, such as, for example, lists of ingredients, areintended to and should be interpreted as Markush groups. Thus, all listscan be read and interpreted as items “selected from the group consistingof’ . . . list of items . . . “and combinations and mixtures thereof.”

Referenced herein may be trade names for components including variousingredients utilized in the present disclosure. The inventors herein donot intend to be limited by materials under any particular trade name.Equivalent materials (e.g., those obtained from a different source undera different name or reference number) to those referenced by trade namemay be substituted and utilized in the descriptions herein.

In the description of the various embodiments of the present disclosure,various embodiments or individual features are disclosed. As will beapparent to the ordinarily skilled practitioner, all combinations ofsuch embodiments and features are possible and can result in preferredexecutions of the present disclosure. While various embodiments andindividual features of the present invention have been illustrated anddescribed, various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. As will also beapparent, all combinations of the embodiments and features taught in theforegoing disclosure are possible and can result in preferred executionsof the invention.

Coated Kibble

Various non-limiting embodiments of the present invention include a petfood in the form of a coated kibble wherein the coated kibble includes acore and a coating at least partially covering the core. In oneembodiment, the pet food, or coated kibble, can be nutritionallybalanced. In one embodiment, the pet food, or coated kibble, can have amoisture, or water, content less than 12%. The kibble can be made andthen coated, or late-stage differentiated, with a layering or coating ofa dry protein source using a binder, which results in a coated kibblehaving an increased animal preference. Still other embodiments of thepresent invention include a method of making a pet food by forming acore mixture and forming a coating mixture and applying the coatingmixture to the core mixture to form a coated kibble pet food. Additionalembodiments of the present invention include a method of making a petfood including two heat treating Salmonella deactivation steps.

One embodiment of the present invention provides a pet food in the formof a coated kibble comprising a core, which can be extruded, a coatingcoated onto the core, wherein the coating comprises a protein componentand a binder component. A depiction of one embodiment of a coated kibbleis shown in FIG. 1. FIG. 1 illustrates a cross-section of a coatedkibble 100. Coated kibble 100 comprises a core 101 and a coating 102that surrounds core 101. While FIG. 1 illustrates a coating completelysurrounding the core, as disclosed herein the coating can only partiallysurround the core. In one embodiment, the coating can comprise from 0.1%to 75% by weight of the entire coated kibble, and the core can comprisefrom 25% to 99.9% of the entire coated kibble. In other embodiments, thecoating can comprise a range of any integer values between 0.1% and 75%by weight of the coated kibble, and the core can comprise a range of anyinteger values between 25% and 99.9% by weight of the coated kibble. Theprotein component can comprise from 50% to 99% of the coating, and thebinder component can comprise from 1% to 50% of the coating. In otherembodiments, the protein component can comprise a range of any integervalues between 50% and 99% by weight of the coating, and the bindercomponent can comprise a range of any integer values between 1% and 50%by weight of the coating. In additional embodiments, the core can have amoisture, or water, content less than 12% and can comprise a gelatinizedstarch matrix, which can be formed by way of the extrusion processdescribed herein.

In one embodiment, the coated kibble comprises a core and a coating. Thecore can comprise several ingredients that form a core matrix. In onenon-limiting example, the core can comprise a carbohydrate source, aprotein source, and/or a fat source. In one embodiment, the core cancomprise from 20% to 100% of a carbohydrate source. In one embodiment,the core can comprise from 0% to 80% of a protein source. In oneembodiment, the core can comprise from 0% to 15% of a fat source. Thecore can also comprise other ingredients as well. In one embodiment, thecore can comprise from 0% to 80% of other ingredients.

The carbohydrate source, or carbohydrate ingredient, or starchingredient, can comprise cereals, grains, corn, wheat, rice, oats, corngrits, sorghum, grain sorghum/milo, wheat bran, oat bran, amaranth,Durum, and/or semolina. The protein source, or protein ingredient, cancomprise chicken meals, chicken, chicken by-product meals, lamb, lambmeals, turkey, turkey meals, beef, beef by-products, viscera, fish meal,entrails, kangaroo, white fish, venison, soybean meal, soy proteinisolate, soy protein concentrate, corn gluten meal, corn proteinconcentrate, distillers dried grains, and/or distillers dried grainssolubles. The fat source, or fat ingredient, can comprise poultry fat,chicken fat, turkey fat, pork fat, lard, tallow, beef fat, vegetableoils, corn oil, soy oil, cottonseed oil, palm oil, palm kernel oil,linseed oil, canola oil, rapeseed oil, fish oil, menhaden oil, anchovyoil, and/or olestra.

Other ingredients can comprise active ingredients, such as sources offiber ingredients, mineral ingredients, vitamin ingredients, polyphenolsingredients, amino acid ingredients, carotenoid ingredients, antioxidantingredients, fatty acid ingredients, glucose mimetic ingredients,Probiotic ingredients, prebiotic ingredients, and still otheringredients. Sources of fiber ingredients can includefructooligosaccharides (FOS), beet pulp, mannanoligosaccharides (MOS),oat fiber, citrus pulp, carboxymethylcellulose (CMC), guar gum, gumarabic, apple pomace, citrus fiber, fiber extracts, fiber derivatives,dried beet fiber (sugar removed), cellulose, a-cellulose,galactooligosaccharides, xylooligosaccharides, and oligo derivativesfrom starch, inulin, psyllium, pectins, citrus pectin, guar gum, xanthangum, alginates, gum arabic, gum talha, beta-glucans, chitins, lignin,celluloses, non-starch polysaccharides, carrageenan, reduced starch, soyoligosaccharides, trehalose, raffinose, stachyose, lactulose,polydextrose, oligodextran, gentioligosaccharide, pecticoligosacchaiide, and/or hemicellulose. Sources of mineral ingredientscan include sodium selenite, monosodium phosphate, calcium carbonate,potassium chloride, ferrous sulfate, zinc oxide, manganese sulfate,copper sulfate, manganous oxide, potassium iodide, and/or cobaltcarbonate. Sources of vitamin ingredients can include choline chloride,vitamin E supplement, ascorbic acid, vitamin A acetate, calciumpantothenate, pantothenic acid, biotin, thiamine mononitrate (source ofvitamin B1), vitamin B12 supplement, niacin, riboflavin supplement(source of vitamin B2), inositol, pyridoxine hydrochloride (source ofvitamin B6), vitamin D3 supplement, folic acid, vitamin C, and/orascorbic acid. Sources of polyphenols ingredients can include teaextract, rosemary extract, rosemarinic acid, coffee extract, caffeicacid, turmeric extract, blueberry extract, grape extract, grapeseedextract, and/or soy extract. Sources of amino acid ingredients caninclude 1-tryptophan, taurine, histidine, carnosine, alanine, cysteine,arginine, methionine, tryptophan, lysine, asparagine, aspartic acid,phenylalanine, valine, threonine, isoleucine, histidine, leucine,glycine, glutamine, taurine, tyrosine, homocysteine, ornithine,citruline, glutamic acid, proline, and/or serine. Sources of carotenoidingredients can include lutein, astaxanthin, zeaxanthin, bixin,lycopene, and/or beta-carotene. Sources of antioxidant ingredients caninclude tocopherols (vitamin E), vitamin C, vitamin A, plant-derivedmaterials, carotenoids (described above), selenium, and/or CoQ10(Co-enzyme Q10). Sources of fatty acid ingredients can includearachidonic acid, alpha-linoleic acid, gamma linolenic acid, linoleicacid, eicosapentanoic acid (EPA), docosahexanoic acid (DHA), and/or fishoils as a source of EPA and/or DHA. Sources of glucose mimeticingredients can include glucose anti-metabolites including2-deoxy-D-glucose, 5-thio-D-glucose, 3-0-methylglucose, anhydrosugarsincluding 1,5-anhydro-D-glucitol, 2,5-anhydro-D-glucitol, and2,5-anhydro-D-mannitol, mannoheptulose, and/or avocado extractcomprising mannoheptulose. Still other ingredients can include beefbroth, brewers dried yeast, egg, egg product, flax meal, DL methionine,amino acids, leucine, lysine, arginine, cysteine, cystine, asparticacid, polyphosphates such as sodium hexametaphosphate (SHMP), sodiumpyrophosphate, sodium tripolyphosphate; zinc chloride, copper gluconate,stannous chloride, stannous fluoride, sodium fluoride, triclosan,glucosamine hydrochloride, chondroitin sulfate, green lipped mussel,blue lipped mussel, methyl sulfonyl methane (MSM), boron, boric acid,phytoestrogens, phytoandrogens, genistein, diadzein, L-carnitine,chromium picolinate, chromium tripicolinate, chromium nicotinate,acid/base modifiers, potassium citrate, potassium chloride, calciumcarbonate, calcium chloride, sodium bisulfate; eucalyptus, lavender,peppermint, plasticizers, colorants, flavorants, sweeteners, bufferingagents, slip aids, carriers, pH adjusting agents, natural ingredients,stabilizers, biological additives such as enzymes (including proteasesand lipases), chemical additives, coolants, chelants, denaturants, drugastringents, emulsifiers, external analgesics, fragrance compounds,humectants, opacifying agents (such as zinc oxide and titanium dioxide),anti-foaming agents (such as silicone), preservatives (such as butylatedhydroxytoluene (BHT) and butylated hydroxyanisole (BHA), propyl gallate,benzalkonium chloride, EDTA, benzyl alcohol, potassium sorbate, parabensand mixtures thereof), reducing agents, solvents, hydrotropes,solubilizing agents, suspending agents (non-surfactant), solvents,viscosity increasing agents (aqueous and non-aqueous), sequestrants,and/or keratolytics.

The Probiotic ingredient or component can comprise one or more bacterialprobiotic microorganism suitable for pet consumption and effective forimproving the microbial balance in the pet gastrointestinal tract or forother benefits, such as disease or condition relief or prophylaxis, tothe pet. Various Probiotic microorganisms are known in the art. See, forexample, WO 03/075676, and U.S. Published Application No. US2006/0228448A1. In specific embodiments, the probiotic component may beselected from bacteria, yeast or microorganism of the genera Bacillus,Bacteroides, Bifidobacterium, Enterococcus (e.g., Enterococcus faeciumDSM 10663 and Enterococcus faecium SF68), Lactobacillus, Leuconostroc,Saccharomyces, Candida, Streptococcus, and mixtures of any thereof. Inother embodiments, the probiotic may be selected from the generaBifidobacterium, Lactobacillus, and combinations thereof. Those of thegenera Bacillus may form spores. In other embodiments, the probioticdoes not form a spore. Non-limiting examples of lactic acid bacteriasuitable for use herein include strains of Streptococcus lactis,Streptococcus cremoris, Streptococcus diacetylactis, Streptococcusthermophilus, Lactobacillus bulgaricus, Lactobacillus acidophilus (e.g.,Lactobacillus acidophilus strain DSM 13241), Lactobacillus helveticus,Lactobacillus bifidus, Lactobacillus casei, Lactobacillus lactis,Lactobacillus plantarum, Lactobacillus rhamnosus, Lactobacillusdelbrukii, Lactobacillus thermophilus, Lactobacillus fermentii,Lactobacillus salvarius, Lactobacillus reuteri, Bifidobacterium longum.Bifidobacterium infantis, Bifidobacterium bifidum, Bifidobacteriumanimalis, Bifidobacterium pseudolongum, and Pediococcus cerevisiae, ormixtures of any thereof. In specific embodiments, the probiotic-enrichedcoating may comprise the bacterial strain Bifidobacterium animalis AHC7NCIMB 41199. Other embodiments of the Probiotic ingredient may includeone or more microorganisms identified in U.S. Published Application Nos.US 2005/0152884A1, US 2005/0158294A1, US 2005/0158293A1, US2005/0175598A1, US 2006/0269534A1 and US 2006/0270020A1 and in PCTInternational Publication No. WO 2005/060707A2.

In at least one embodiment, a coating can be coated onto the core,described hereinabove. In at least one embodiment, the coating can beapplied to the core to increase the animal preference, or pet acceptanceor preference, of the coated kibble. Thus, the uncoated core can belate-stage differentiated by applying a coating, which can increase theanimal preference and thus the pet acceptance or preference for thefinal coated kibble. In one embodiment, this uncoated core can be a corethat has been already processed, including milling, conditioning,drying, and/or extruded, all as described herein.

The coating can comprise several coating components, or agents, thatform a coating to coat the core of the kibble. In one non-limitingexample, the coating can comprise a protein component and a bindercomponent. In one embodiment, the coating can comprise from 50% to 99%of a protein component and from 1% to 50% of a binder component. Thecoating can also comprise other components as well, which can be appliedwith the protein component and/or binder component, or can be appliedafter application of the protein and/or binder component. In oneembodiment, the coating can comprise from 0% to 70% of a palatantcomponent. In one embodiment, the coating can comprise from 0% to 50% ofa fat component. In one embodiment, the coating can comprise from 0% to50% of other components.

In one embodiment, the coated kibble can have more than one coating.Thus, a first coating, second coating, third coating, and so on can beincluded. Each of these coatings can be comprised of any of the coatingcomponents as described herein.

In any of the embodiments described herein, the coating components canbe considered a solids coating, solids component, or solids ingredient.Thus, this solids coating can comprise less than 12% moisture, or water,content. In one embodiment, the coating component comprises a proteincomponent as a solids coating having less than 12% moisture, or water,content.

The coating as described herein can be a partial or complete covering onthe surface of the core. In one example, a core may be partially coveredwith a coating such that only part of the core is covered, and part ofthe core is not covered and is thus exposed. In another example, thecore may be completely covered with a coating such that the entire coreis covered and thus not exposed. A coating can also be coated onto othercoatings such that a layering of coatings can be present. For example, acore can be completely coated with a first coating component, and thefirst coating component can be completely coated with a second coatingcomponent such that the first coating component and the second coatingcomponent each form a separate layer. Of course, additional coatingcomponents can be added, such as third, fourth, fifth, sixth, up to thedesired number of coating components. In one embodiment, each can form aseparate layer. In another embodiment, each can form partial layers. Inone embodiment, a plurality of coating components can form a singlelayer, and each layer more can be formed from one or a plurality ofcoating components.

The protein component can comprise chicken meals, chicken, chickenby-product meals, lamb, lamb meals, turkey, turkey meals, beef, beefby-products, viscera, fish meal, entrails, kangaroo, white fish,venison, soybean meal, soy protein isolate, soy protein concentrate,corn gluten meal, corn protein concentrate, distillers dried grains,distillers dried grains solubles, and single-cell proteins, for exampleyeast, algae, and/or bacteria cultures. One embodiment of a proteincomponent comprises chicken by-product meal at less than 12% moisture,or water.

The binder component can comprise any of the following or combinationsof the following materials: monosaccharides such as glucose, fructose,mannose, arabinose; di- and trisaccharides such as sucrose, lactose,maltose, trehalose, lactulose; corn and rice syrup solids; dextrins sucha corn, wheat, rice and tapioca dextrins; maltodextrins; starches suchas rice, wheat, corn, potato, tapioca starches, or these starchesmodified by chemical modification; oligosaccharides such asfructooligosccharides, alginates, chitosans; gums such as carrageen, andgum arabic; polyols such as glycerol, sorbitol, mannitol, xylitol,erythritol; esters of polyols such as sucrose esters, polyglycol esters,glycerol esters, polyglycerol esters, sorbitan esters; sorbitol;molasses; honey; gelatins; peptides; proteins and modified proteins suchas whey liquid, whey powder, whey concentrate, whey isolate, wheyprotein isolate, high lactose whey by-product, such as DAIRYLAC® 80 fromInternational Ingredient Corporation, meat broth solids such as chickenbroth, chicken broth solids, soy protein, and egg white. Theseaforementioned binder components can be used in combination with water,especially when added. The binder material can be dissolved or dispersedin water, forming a liquid mixture or solution, which can then beapplied over the surface of the core. The liquid mixture can facilitateboth even dispersion of the binder component over the core surface andthe interaction between the core surface and the protein component beingapplied to the surface of the core. In one embodiment, the liquidmixture can be an about 20% liquid mixture of binder component, whichcan be added to the kibble at 5% to 10% by weight of the kibble, which,on a dry matter basis, becomes about 1% to 2% by weight of the kibble.

In embodiments when a binder component is used, keeping the bindercomponent on the surface of the core can be done, thus preventing, or atleast attempting to minimize, absorption of the binder towards and intothe core. In one embodiment, additives can be added to increase theviscosity of the binder solution. Those additives can be corn starch,potato starch, flour, and combinations and mixtures thereof. Theseadditives can assist in keeping the binder component on the surface ofthe kibble to prevent or minimize absorption from the surface towardsand into the core. In another embodiment, varying the temperature of thebinder solution to thicken the solution can be done. For example, whenusing egg white as a binder component, denaturization of the proteins ofthe egg whites can create a gel-like solution. This formation of agel-like solution can occur around 80° C., so in one embodiment raisingthe temperature of the binder solution to 80° C. can be performed.Additionally, the temperature of the core can be increased to alsoassist in minimizing the absorption of the binder towards the core. Inanother embodiment, additives and temperature variation as justdescribed can also be done in combination.

Thus, in one embodiment, the binder component can act as a glue, oradhesive material, for the protein component to adhere to the core. Inone embodiment, the protein component can be a solids ingredient at lessthan 12% moisture, or water, content, and the binder component can be aliquid. In one embodiment, the binder component can be applied to orlayered onto the core to act as the glue for the protein component,which can then be applied to or layered onto the core with bindercomponent. In another embodiment, the protein component as a solidsingredient can be mixed with the binder component, and then the mixturecan be applied to or layered onto the core.

In one embodiment, lipids and lipid derivatives can also be used asbinder components. Lipids can be used in combination with water and/orother binder components. Lipids can include plant fats such as soybeanoil, corn oil, rapeseed oil, olive oil, safflower oil, palm oil, coconutoil, palm kernel oil, and partially and fully hydrogenated derivativesthereof; animal fats and partially and fully hydrogenated derivativesthereof; and waxes.

In one embodiment, it can be advantageous to minimize the interfacialtension between the coating and the kibble. Emulsifiers can be used inone embodiment to minimize such repulsive forces. The emulsifier cancomprise an emulsifier comprising a plurality of hydroxyl groups. Inother embodiments, emulsifiers such as mono- and diglycerides of fattyacids, mono- and diacetyl tartaric acid esters of mono- and diglyceridesof fatty acids, sodium and calcium stearoyl-2-lactylates, mono- anddiacetyl tartaric acid esters of mono- and diglycerides of fatty acidsand sucrose esters of fatty acids, citric acid esters of mono- anddiglycerides of fatty acids, lactic acid esters of mono- anddiglycerides of fatty acids and polyglycerol esters, lecithins,polyglycerol esters and polysorbate esters can be mixed with thecoating, forming an emulsifier and coating composition. Such emulsifiercan be used to minimize the surface energy and interfacial tensionbetween the coating and the kibble surface. Minimization of the surfaceenergy of the coating has been associated with better adherence of thecoating to the kibble by lowering the interfacial tension. Coatings canbe any of the coatings as disclosed herein. Particular emulsifiers caninclude polysorbate esters such as Polysorbate 80. In one embodiment,the emulsifier can be used at from about 0.01% to about 10% by weight ofthe coating and emulsifier composition. Thus, the coating can be fromabout 90% to about 99.99% by weight of the coating and emulsifiercomposition. In other embodiments, the emulsifier can be present at fromabout 0.1% to about 2%, or from about 0.1% to about 1%, or from about0.5% to about 1%, by weight. Accordingly, the coating can be from about98% to about 99.9%, or from about 99% to about 99.9, or from about 99%to about 99.5%, by weight.

The surface energy is understood to mean the average surface energy of arepresentative area of a compressed powder, although localizedvariations may occur due to such factors as variation in mixing orgrinding and texture. The surface energy of the compressed powdercorrelates to hydrophobicity and hydrophilicity, and may berepresentative of, for example, the moisture content of the powder. Thesurface energy of the compressed pellet is derived from contact anglemeasurements of liquids of known surface tension, which can be convertedto surface energy by various accepted models that would be known to oneof skill in the art. One such model, used in the present invention, isthe Fowkes equation, as described in Fowkes, F. M.: Industrial andEngineering Chemistry, vol. 56, number 12, p. 40 (1964):

γ_(lv)(1+cos θ)=2(γ_(lV) ^(d)γ_(SV) ^(d))^(1/2)+2(γ_(lV) ^(P)γ_(SV)^(P))^(1/2)

where 0 refers to the contact angle; γ_(lV) refers to the surfacetension of the liquid (solvent of known surface tension); γ_(lV) ^(d);refers to the dispersive component of the surface tension of the liquid;γ_(SV) ^(d) refers to the dispersive component of the surface tension ofthe solid (compressed pellet); γ_(lV) ^(P) refers to the polar componentof the surface tension of the liquid and γ_(SV) ^(P) refers to the polarcomponent of the surface tension of the solid. The contact angles of thecompressed pellet herein were measured using diiodomethane (99%,Aldrich), formamide (99%+, Aldrich) and water (HPLC grade, Aldrich). Thetotal surface energy of the compressed pellet is the sum of thedispersive surface energy component and the polar surface energycomponent, which is thought to affect properties such as adhesion ofsubstances to the kibble.

A palatant component can be used in some embodiments. The palatant cancomprise chicken flavor, such as liquid digest derived from chickenlivers, which can be approximately 70% water and chicken liver digests.A palatant component as used herein means anything that is added to theanimal feed for the primary purpose of improving food acceptance, orpreference, by the animal. A palatant component, which can also beconsidered a flavor, a flavoring agent, or a flavoring component, caninclude a liver or viscera digest, which can be combined with an acid,such as a pyrophosphate. Non-limiting examples of pyrophosphatesinclude, but are not limited to, disodium pyrophosphate, tetrasodiumpyrophosphate, trisodium polyphosphates, tripolyphosphates, and zincpyrophosphate. The palatant component can contain additional palatantaids, non-limiting examples of which can include methionine and choline.Other palatant aids can include aromatic agents or other entities thatdrive interest by the animal in the food and can includecyclohexanecarboxylic acid, peptides, monoglycerides, short-chain fattyacids, acetic acid, propionic acid, butyric acid, 3-methylbutyrate,zeolite, poultry hydrolysate, tarragon essential oil, oregano essentialoil, 2-methylfuran, 2-methylpyrrole, 2-methyl-thiophene, dimethyldisulfide, dimethyl sulfide, sulfurol, algae meal, catnip,2-Piperidione, 2,3 pentanedione, 2-ethyl-3,5-dimethypyrazine, Furfural,Sulfurol, and Indole. In addition, various meat based flavorants oraroma agents can be used, non-limiting examples include meat, beef,chicken, turkey, fish, cheese, or other animal based flavor agents.

The fat component can comprise poultry fat, chicken fat, turkey fat,pork fat, lard, tallow, beef fat, vegetable oils, corn oil, soy oil,cottonseed oil, palm oil, palm kernel oil, linseed oil, canola oil,rapeseed oil, fish oil, menhaden oil, anchovy oil, and/or olestra.

The other components can comprise active ingredients, such as sources offiber ingredients, mineral ingredients, vitamin ingredients, polyphenolsingredients, amino acid ingredients, carotenoid ingredients, antioxidantingredients, fatty acid ingredients, glucose mimetic ingredients,Probiotic ingredients, prebiotic ingredients, and still otheringredients. Sources of fiber ingredients can includefructooligosacchalides (FOS), beet pulp, mannanoligosacchalides (MOS),oat fiber, citrus pulp, carboxymethylcellulose (CMC), guar gum, gumarabic, apple pomace, citrus fiber, fiber extracts, fiber delivatives,dried beet fiber (sugar removed), cellulose, a-cellulose,galactooligosacchalides, xylooligosaccharides, and oligo derivativesfrom starch, inulin, psyllium, pectins, citrus pectin, guar gum, xanthangum, alginates, gum arabic, gum talha, beta-glucans, chitins, lignin,celluloses, non-starch polysacchalides, carrageenan, reduced starch, soyoligosaccharides, trehalose, raffinose, stachyose, lactulose,polydextrose, oligodextran, gentioligosacchalide, pecticoligosacchalide, and/or hemicellulose. Sources of mineral ingredientscan include sodium selenite, monosodium phosphate, calcium carbonate,potassium chloride, ferrous sulfate, zinc oxide, manganese sulfate,copper sulfate, manganous oxide, potassium iodide, and/or cobaltcarbonate. Sources of vitamin ingredients can include choline chloride,vitamin E supplement, ascorbic acid, vitamin A acetate, calciumpantothenate, pantothenic acid, biotin, thiamine mononitrate (source ofvitamin B1), vitamin B12 supplement, niacin, riboflavin supplement(source of vitamin B2), inositol, pyridoxine hydrochloride (source ofvitamin B6), vitamin D3 supplement, folic acid, vitamin C, and/orascorbic acid. Sources of polyphenols ingredients can include teaextract, rosemary extract, rosemarinic acid, coffee extract, caffeicacid, turmeric extract, blueberry extract, grape extract, grapeseedextract, and/or soy extract. Sources of amino acid ingredients caninclude 1-Tryptophan, Taurine, Histidine, Carnosine, Alanine, Cysteine,Arginine, Methionine, Tryptophan, Lysine, Asparagine, Aspartic acid,Phenylalanine, Valine, Threonine, Isoleucine, Histidine, Leucine,Glycine, Glutamine, Taurine, Tyrosine, Homocysteine, Ornithine,Citruline, Glutamic acid, Proline, and/or Serine. Sources of carotenoidingredients can include lutein, astaxanthin, zeaxanthin, bixin,lycopene, and/or beta-carotene. Sources of antioxidant ingredients caninclude tocopherols (vitamin E), vitamin C, vitamin A, plant-derivedmaterials, carotenoids (described above), selenium, and/or CoQ10(Co-enzyme Q10). Sources of fatty acid ingredients can includearachidonic acid, alpha-linoleic acid, gamma linolenic acid, linoleicacid, eicosapentanoic acid (EPA), docosahexanoic acid (DHA), and/or fishoils as a source of EPA and/or DHA. Sources of glucose mimeticingredients can include glucose anti-metabolites including2-deoxy-D-glucose, 5-thio-D-glucose, 3-0-methylglucose, anhydrosugarsincluding 1,5-anhydro-D-glucitol, 2,5-anhydro-D-glucitol, and2,5-anhydro-D-mannitol, mannoheptulose, and/or avocado extractcomprising mannoheptulose. Still other ingredients can include beefbroth, brewers dried yeast, egg, egg product, flax meal, DL methionine,amino acids, leucine, lysine, arginine, cysteine, cystine, asparticacid, polyphosphates such as sodium hexametaphosphate (SHMP), sodiumpyrophosphate, sodium tripolyphosphate; zinc chloride, copper gluconate,stannous chloride, stannous fluoride, sodium fluoride, triclosan,glucosamine hydrochloride, chondroitin sulfate, green lipped mussel,blue lipped mussel, methyl sulfonyl methane (MSM), boron, boric acid,phytoestrogens, phytoandrogens, genistein, diadzein, L-carnitine,chromium picolinate, chromium tripicolinate, chromium nicotinate,acid/base modifiers, potassium citrate, potassium chloride, calciumcarbonate, calcium chloride, sodium bisulfate; eucalyptus, lavender,peppermint, plasticizers, colorants, flavorants, sweeteners, bufferingagents, slip aids, carriers, pH adjusting agents, natural ingredients,stabilizers, biological additives such as enzymes (including proteasesand lipases), chemical additives, coolants, chelants, denaturants, drugastringents, emulsifiers, external analgesics, fragrance compounds,humectants, opacifying agents (such as zinc oxide and titanium dioxide),anti-foaming agents (such as silicone), preservatives (such as butylatedhydroxytoluene (BHT) and butylated hydroxyanisole (BHA), propyl gallate,benzalkonium chlolide, EDTA, benzyl alcohol, potassium sorbate, parabensand mixtures thereof), reducing agents, solvents, hydrotropes,solubilizing agents, suspending agents (non-surfactant), solvents,viscosity increasing agents (aqueous and non-aqueous), sequestrants,and/or keratolytics.

The Probiotic ingredient or component can comprise one or more bacterialProbiotic microorganisms suitable for pet consumption and effective forimproving the microbial balance in the pet gastrointestinal tract or forother benefits, such as disease or condition relief or prophylaxis, tothe pet. Various Probiotic microorganisms are known in the art. See, forexample, WO 03/075676, and U.S. Published Application No. US2006/0228448A1. In specific embodiments, the probiotic component may beselected from bacteria, yeast or microorganism of the genera Bacillus,Bacteroides, Bifidobacterium, Enterococcus (e.g., Enterococcus faeciumDSM 10663 and Enterococcus faecium SF68), Lactobacillus, Leuconostroc,Saccharomyces, Candida, Streptococcus, and mixtures of any thereof. Inother embodiments, the Probiotic may be selected from the generaBifidobacterium, Lactobacillus, and combinations thereof. Those of thegenera Bacillus may form spores. In other embodiments, the Probioticdoes not form a spore. Non-limiting examples of lactic acid bacteriasuitable for use herein include strains of Streptococcus lactis,Streptococcus cremoris, Streptococcus diacetylactis, Streptococcusthermophilus, Lactobacillus bulgaricus, Lactobacillus acidophilus (e.g.,Lactobacillus acidophilus strain DSM 13241), Lactobacillus helveticus,Lactobacillus bifidus, Lactobacillus casei, Lactobacillus lactis,Lactobacillus plantarum, Lactobacillus rhamnosus, Lactobacillusdelbrukii, Lactobacillus thermophilus, Lactobacillus fermentii,Lactobacillus salvarius, Lactobacillus reuteri, Bifidobacterium longum,Bifidobacterium infantis, Bifidobacterium bifidum, Bifidobacteriumanimalis, Bifidobacterium pseudolongum, and Pediococcus cerevisiae, ormixtures of any thereof. In specific embodiments, the Probiotic-enrichedcoating may comprise the bacterial strain Bfidobacterium animalis AHC7NCIMB 41199. Other embodiments of the Probiotic ingredient may includeone or more microorganisms identified in U.S. Published Application Nos.US 2005/0152884A1, US 2005/0158294A1, US 2005/0158293A1, US2005/0175598A1, US 2006/0269534A1, and US 2006/0270020A1 and in PCTInternational Publication No. WO 2005/060707A2.

These active ingredients can be provided in any form, such as in a dryform. A dry form of an active can be a form that comprises less than 12%moisture, or water, and thus can be considered a solids ingredient.Thus, in one embodiment, a Probiotic component can be provided in a dryform as a powder, such as with an average particle size of less than 100micrometers. At less than 100 micrometers, the Probiotic component canbe adhered more easily to the kibble. In one embodiment, Probioticcomponents can have a particle size greater than 100 micrometers.However, in this embodiment, more binder can be used to aid in adherenceof the Probiotic to the kibble. The Probiotic component in the form of adry powder can be applied as part of the coating to the core, resultingin a coated kibble having a Probiotic in the coating.

Thus, the coating can comprise active ingredients. Therefore, oneembodiment of the present invention relates to a method of deliveringactive ingredients to a pet or animal, wherein the active ingredientscan comprise any of the active ingredients disclosed herein, includingmixtures and combinations thereof. In one embodiment, a pet food in theform of a coated kibble is provided. The coated kibble can comprise acore as described herein, and the coated kibble can comprise a coatingas disclosed herein. In one embodiment, the coating comprises coatingcomponents, comprising a protein component as disclosed herein, a bindercomponent as described herein, a fat component as described herein, apalatant component as described herein, and active ingredients asdescribed herein. In one embodiment, the protein component, the fatcomponent, and the palatant component, and combinations and mixturesthereof, can act as a carrier for the active ingredient. In anotherembodiment, the active ingredients can be a solids ingredient, such thatthe moisture, or water, content is less than 12%. The pet food in theform of a coated kibble, comprising active ingredients, can be providedto a pet or animal for consumptions. The active ingredient can comprisefrom 0.01% to 50% of the coating.

Thus, embodiments of the present invention contemplate coated kibblescomprising at least one active ingredient. Thus, one embodiment of thepresent invention relates to delivering active ingredients through acoated kibble in accordance with embodiments of the coated kibble asdisclosed herein. It has been found that a coated kibble of embodimentsof the present invention can increase animal preference of the coatedkibble comprising an active ingredient and can increase the stability ofthe active ingredient.

Still other components can comprise components that can assist inreducing water transmission within the coated kibble. Components caninclude cocoa butter, palm kernel oil, palm oil, cottonseed oil, soybeanoil, canola oil, rapeseed oil, hydrogenated derivatives of oils or fats,paraffin, wax, liquid paraffin, solid paraffin, candelilla wax, carnaubawax, microcrystalline wax, beeswax, capric acid, myristic acid, palmiticacid, stearic acid, acetyl acyl glycerols, shellac, dewaxed gumlac,triolein, peanut oil, chocolate, methylcellulose, stearic acid,hydroxypropylmethylcellulose, glycerol monostearate, methylcellulose,polyethylene glycol, behinic acid, adipic acid, carboxymethylcellulose,butter oil, pectin, acetylated monoglyceride, wheat gluten, oleic acid,soy lecithin, paraffin wax, paraffin oil, sodium caseinate, lauric acid,whey protein isolate, whey protein concentrate, stearyl alcohol,olestra, acetylated monoglycerides, chocolate liquor, sweet milkchocolate, cocoa solids, tristearin, animal fat, and/or poultry fat.

In one embodiment of the present invention, the protein component of thecoating can be a dry component, or a solids ingredient, such that thewater content of the protein component is less than 12%. Therefore, inthis embodiment, the protein component, or solids ingredient, can act asa solid-like material that can be coated onto a core by using a binderingredient. A protein component having less than 12% moisture, or water,can be extremely difficult to coat onto a core, or kibble, which itselfcan have a low moisture, or water, content, even less than 12%, asdescribed herein. Thus, a binder component can assist in the coating ofthe dry protein component onto the core, or kibble.

In one embodiment, the finished coated kibble can comprise from 80% to90% core and from 10% to 20% coating. The core can comprise from 45% to55% carbohydrate source, from 35% to 45% protein source, from 0.1% to 5%fat source, and from 5% to 10% other ingredients. The coating cancomprise from 65% to 75% protein component, a non-limiting example ofwhich can be chicken by-product meal, from 5% to 10% binder component, anon-limiting example of which can be egg white, high lactose wheyby-product, whey protein isolate or chicken broth, from 15% to 25% fatcomponent, a non-limiting example of which can be chicken fat, and from1% to 10% palatant component, a non-limiting example of which can bechicken liver digest. The coated kibble can comprise less than 12%water.

Macronutrients that can be included in the kibble of embodiments of thepresent invention can include protein sources/ingredients/components,fat sources/ingredients/components, and carbohydratesources/ingredients/components, and mixtures and combinations thereof,all as described hereinabove. The macronutrient can be selected from thegroup consisting of protein sources/ingredients/components, fatsources/ingredients/components, carbohydratesources/ingredients/components, and combinations and mixtures thereof,all as described hereinabove. These macronutrients can be distributedbetween the core and the coating such that the core comprises aparticular amount of the macronutrients, and the coating comprises aparticular amount of the macronutrients, all as a whole. In oneembodiment, the distribution of the macronutrients between the core andthe coating can be in a ratio of 12 to 1. In one embodiment, thedistribution of the macronutrients between the core and the coating canbe in a ratio of 1 to 12. In one embodiment, the distribution of themacronutrients between the core and the coating can be between a ratioof 12 to 1 and 1 to 12 and all integer values therebetween. Thedistribution of the macronutrients, as described, is as a mixture of themacronutrients of protein sources/ingredients/components, fatsources/ingredients/components, and carbohydratesources/ingredients/components. Thus, in one embodiment in which thedistribution of macronutrients ratio is 12 to 1 between the core and thecoating, this embodiment represents a distribution of total proteinsources/ingredients/components, fat sources/ingredients/components, andcarbohydrate sources/ingredients/components, as a sum, of 12 to 1between the core and the coating. Thus, in this embodiment, a ratio of12 units of protein plus fat plus carbohydrate to 1 unit of protein plusfat plus carbohydrate exists.

Process

The kibble embodiments of the present invention may be formed by anextrusion process whereby the core ingredients, after formed into a corematrix, as described hereinabove, are extruded under heat and pressureto form a pelletized kibble form, or core pellet. During the extrusionprocess, if a starch matrix is employed, it may and typically doesbecome gelatinized under the extrusion conditions.

In one embodiment, the extruding of the core matrix may be done using asingle screw extruder, while other embodiments may be done using atwin-screw extruder. Extrusion of the core matrix may require specificconfigurations of the extruder to produce a material suitable for akibble pet food. For example, very high shears and low extrusion timesmay be necessary to prevent significant color degradation and preventpolymerization of the material within the extruder and to producekibbles that are durable for further processing, such as coating withone or more coatings.

In one embodiment, the coated kibble may be manufactured by contacting amass of core pellets, such as may be produced by extrusion, and acoating component in a counter-rotating dual-axis paddle mixer.

In one embodiment, the ingredients used for a core matrix for forminginto a core, or core material, may be any individual startingcomponents, including, but not limited to, the sources/ingredientsdescribed hereinabove.

Processes common to making dry pet foods are milling, batching,conditioning, extrusion, drying, and coating. Milling encompasses anyprocess used to reduce whole or partial ingredients into smaller forms.Whole or partial formulations are created in the process step forbatching by mixing dry and/or liquid ingredients. Often theseingredients are not in the most nutritious or digestible form and thusprocesses are needed to further convert these ingredients to adigestible form via some sort of cooking process.

During the milling process, the individual starting components of thecore material can be mixed and blended together in the desiredproportions to form the core material. In one embodiment, the resultingcore material may be screened to remove any large agglomerate ofmaterial therefrom. Any sort of conventional solids mixer can be usedfor this step including, but not limited to, plough mixers, paddlemixers, fluidizing mixers, conical mixers, and drum mixers. One skilledin the art of solids mixing would be able to optimize the mixingconditions based on the types of materials, particle sizes, and scale,from any one of a number of widely available textbooks and articles onthe subject of solids mixing.

The core material mixture can then be fed into a conditioner.Conditioning may be used to pretreat the ingredients and can includehydration, addition/mixing of other ingredients, and partial cooking.Cooking can often be accomplished by the addition of heat in the form ofsteam and can result in discharge temperatures of from 113° F. to 212°F. Pressurized conditioning may be used when temperatures need to beelevated above standard atmospheric conditions, such as at greater than212° F. Conditioned ingredients and/or ingredients, or combinationsthereof, can then be transferred to an extruder for further processing.

The core material, so conditioned, can then be subjected to an extrusionoperation in order to obtain an expanded core pellet. In one embodiment,the core material may be routed to a hopper prior to the extrusionoperation. The extruder may be any suitable single or twin screw cookingextruder. Suitable extruders may be obtained from Wenger ManufacturingInc., Clextral SA, Buhler AG, and the like. The extruder operatingconditions may vary depending on the particular product to be made. Forexample, the texture, hardness, or bulk density of the extruded productmay be varied using changes in the extruder operating parameters.Similar to conditioning, extrusion can be used to incorporate otheringredients (non-limiting examples of which are carbohydrates, proteins,fats, vitamins, minerals, and preservatives) by having dry and/or liquidingredient streams added anywhere along the length of the extruder feedport, barrel, or die. Extruders are often, but not limited to, single-or twin-screw in design and operate up to 1700 rpm. The extrusionprocess can often be accompanied with high pressure (up to 1500 15 psig)and high temperature (up to 250° C.). Extrusion can be used toaccomplish the making of continuous ropes or sheets but also discreteshapes and sizes of edible food. These forms, shapes, and sizes areoften the result of forcing the materials through a die or set of dieopenings and cutting or breaking into smaller segments.

At this stage, the extruded product can be in any form, such as extrudedropes, sheets, shapes, or other segments, and can be in an expandedmoist pellet form that can then be transferred to post-extrusionoperations. These can include crimping, shredding, stamping, conveying,drying, cooling, and/or coating in any combination or multiple of these.Crimping is any process that pinches food together. Shredding is anyprocess that reduces the size of the food upon extrusion, preferably bytearing. Stamping is any process that embosses a surface or cuts througha food. Conveying is used to transport food from one operation toanother and may change or maintain the state of the food duringtransport; often this process is mechanical or pneumatic. Drying can beused to reduce process moisture, or water, to levels suitable forshelf-life in the finished product. As an expanded moist pellet, such asa kibble, the pellets can be transported from the extruder outlet to adryer, such as a dryer oven, by a conveying, airveying, or auguringsystem. After expansion and transport to the entrance to the dryer, thekibbles can typically have been cooled to between 85° C. and 95° C. andkibble moisture, or water, reduced by evaporation from about 25-35% toabout 20-28%. The temperature of the drying oven may be from 90° C. to150° C. The temperature of the core pellets exiting the drying oven maybe from 90° C. to 99° C. At this stage, coating of the pellets can beperformed. Coating can be performed to add carbohydrates, proteins,fats, water, vitamins, minerals, and other nutritional or health benefitingredients to the food to make an intermediate or finished product.Cooling of the core pellets can be used to reduce the temperature fromextrusion and/or drying.

Thus, at this stage, the core pellets, or core, can be considered cookedsuch that any starch component that was used can be gelatinized. Thecore pellets can then be fed to a fluidizing mixer for the applicationof a coating in the manufacture of a food pellet, such as a coatedkibble. In one embodiment, the core pellets may be routed to a hopperprior to entering the fluidizing mixer. The coated kibble may be formedby contacting the core with a coating in a fluidizing mixer. In oneembodiment, the fluidizing mixer can be a counter-rotating dual-axispaddle mixer, wherein the axes can be oriented horizontally with paddlesattached to the counter-rotating axes. A suitable counter-rotatingdual-axis paddle mixer may be obtained from Forberg International AS,Larvik, Norway; Eirich Machines, Inc, Gurnee, Ill., USA, and Dynamic AirInc., St. Paul, Minn., USA. The motion of the paddles in-between theshafts constitutes a converging flow zone, creating substantialfluidization of the particles in the center of the mixer. Duringoperation of the mixer, the tilt of paddles on each shaft may createopposing convective flow fields in the axial directions generating anadditional shear field in the converging flow zone. The downwardtrajectory of the paddles on the outside of the shafts constitutes adownward convective flow.

In one embodiment, the fluidizing mixer can have a converging flow zonelocated in-between the counter-rotating paddle axes. In one aspect, theswept volumes of said counter-rotating paddle axes overlap within theconverging flow zone. As used herein, the term “swept volume” means thevolume that is intersected by a mixing tool attached to a rotating shaftduring a full rotation of the shaft. In one aspect, the swept volumes ofthe counter-rotating paddle axes do not overlap within the convergingflow zone. In one aspect, a gap can exist in the converging flow zonebetween the swept volumes of the counter-rotating paddle axes.

As described above, in one embodiment, the coating can comprise aprotein component and a binder component. In one embodiment, the proteincomponent and the binder component are mixed together into a singlemixture or pre-mixed coating, prior to addition to the mixer. In anotherembodiment, the protein component and the binder component are not mixedtogether into a single mixture prior to addition to the mixer.

In one embodiment, the pre-mixed coating can be introduced or fed intothe counter-rotating dual-axis paddle mixer such that the pre-mixedcoating is directed upward into the converging zone between thecounter-rotating paddle axes. The counter-rotating dual axis paddlemixer can have a converging flow zone between the counter-rotatingpaddle axes. Either overlapping or non-overlapping paddles can be used.The pre-mixed coating can be directed into the gap between the sweptvolumes of the counter-rotating paddle axes. In one aspect, the ingressof the pre-mixed coating into the dual-axis paddle mixer can occurthrough a distributor pipe located below the converging flow zone of thecounter-rotating paddle axes. The distributor pipe can comprise at leastone opening through which the coating passes into the dual-axis paddlemixer. In one aspect, the ingress of the pre-mixed coating into thedual-axis paddle mixer can occur by adding the pre-mixed coating alongthe side or sides of the mixer, preferably the sides parallel to thepaddles axles. Material is swept downward to the bottom of the mixer andthen is swept back upward into the converging flow zone of thecounter-rotating paddle axes.

In one embodiment, the pre-mixed coating can be introduced into thecounter-rotating dual-axis paddle mixer such that the pre-mixed coatingis directed downward on top of the converging zone between thecounter-rotating paddle axes. In one embodiment, the pre-mixed coatingcan be introduced into the counter-rotating dual-axis paddle mixer suchthat the pre-mixed coating is directed downward into the convective flowon the outside of the counter-rotating paddle axes.

In one embodiment, the coating components, such as the proteincomponent, fat component, binder component, and/or palatant component,and combinations and mixtures thereof, can be separately introduced intothe counter-rotating dual-axis paddle mixer such that the coatingcomponents are directed upward into the converging zone between thecounter-rotating paddle axes. The counter-rotating dual axis paddlemixer may have a converging flow zone between the counter-rotatingpaddle axes. The coating components can be directed into the gap betweenthe swept volumes of the counter-rotating paddle axes. In one aspect,the ingress of the coating components into the dual-axis paddle mixercan occur through a distributor pipe located below the converging flowzone of the counter-rotating paddle axes. The distributor pipe maycomprise at least one opening through which the coating component passesinto the dual-axis paddle mixer. In one aspect, the ingress of thecoating component into the dual-axis paddle mixer can occur by addingthe separate coating component along the side or sides of the mixer,preferably the sides parallel to the paddles axles. Material is sweptdownward though to the bottom of the mixer and then is swept back upwardinto the converging flow zone of the counter-rotating paddle axes.

In one embodiment, the coating components can be separately introducedinto the counter-rotating dual-axis paddle mixer such that the coatingcomponents are directed downward on top of the converging zone betweenthe counter-rotating paddle axes. In one embodiment, the coatingcomponents can be introduced into the counter-rotating dual-axis paddlemixer such that the coating components are directed downward into theconvective flow on the outside of the counter-rotating paddle axes.

In one embodiment, the protein component can be introduced into thecounter-rotating dual-axis paddle mixer such that the protein componentis directed upward into the converging zone between the counter-rotatingpaddle axes. The counter-rotating dual axis paddle mixer can have aconverging flow zone between the counter-rotating paddle axes. Theprotein component can be directed into the gap between the swept volumesof the counter-rotating paddle axes. In one aspect, the ingress of theprotein component into the dual-axis paddle mixer can occur through adistributor pipe located below the converging flow zone of thecounter-rotating paddle axes. The distributor pipe may comprise at leastone opening through which the protein component passes into thedual-axis paddle mixer. In one aspect, the ingress of the proteincomponent into the dual-axis paddle mixer can occur by adding theprotein component along the side or sides of the mixer, preferably thesides parallel to the paddles axles. Material is swept downward to thebottom of the mixer and then is swept back upward into the convergingflow zone of the counter-rotating paddle axes.

In one embodiment, the binder component can be introduced into thecounter-rotating dual-axis paddle mixer such that the binder componentis directed downward on top of the converging zone between thecounter-rotating paddle axes.

In one embodiment, a single fluidizing mixing unit can be employed. Inone embodiment, multiple fluidizing mixing units are employed such as,for example, cascading mixers of different coating components forcoating on the core pellet. In one embodiment, multiple mixers may beemployed, such as, for example, cascading mixers of progressivelyincreasing volume capacity. It is believed that the increase in volumecapacity may accommodate an increase in product capacity. In oneembodiment, the coating process can occur at least once. In oneembodiment, the coating process may occur as many times as desired tomanufacture the desired food pellet. In one embodiment, the coatingprocess may be repeated as many times as determined to be sufficient byone of ordinary skill to increase the core pellet mass by a factor ofmore than about 1.04 to about 4 when compared to the initial mass of thecore pellet.

In one embodiment, the binder component can be introduced into themixing unit. Application of the binder component can begin prior toapplication of the protein component. After the beginning of theapplication of the binder component, but while binder component is stillbeing applied, application of the protein component can begin. Thus, acore coated with a binder component and a protein component can beformed. After this coated core is formed, a Salmonella deactivationstep, as described hereinafter, can be performed. After this Salmonelladeactivation step, a fat component and a palatant component can beintroduced into the mixing unit as additional coating components.

In one embodiment, the protein component and the binder component can beintroduced into the mixing unit as coating components at substantiallythe same time. Thus, a core coated with a binder component and a proteincomponent can be formed. After this coated core is formed, a Salmonelladeactivation step, as described hereinafter, can be performed. Afterthis Salmonella deactivation step, a fat component and a palatantcomponent can be introduced into the mixing unit as additional coatingcomponents.

In other embodiments, application of the protein component, bindercomponent, fat component, and palatant component can be performed in anyorder and with any amount of overlapping of application times.

In one embodiment, the gap between a paddle tip and fluidizing mixerwall can be greater than the largest dimension of the core pellet beingcoated. While not being bound by theory, it is believed that such a gapclearance prevents the core pellets from becoming lodged between thepaddle tip and the wall, possibly causing core pellet breakage.

In one embodiment, the gap between a paddle tip and fluidizing mixerwall can be smaller than the smallest dimension of the core pellet beingcoated. While not being bound by theory, it is believed that such a gapclearance prevents the core pellets from becoming lodged between thepaddle tip and the wall, possibly causing core pellet breakage.

In one embodiment, the temperature of the core pellets at the start ofthe coating process is from 1° C. to 40° C. lower than the melting pointtemperature of the higher melting point temperature component. Too highof a core pellet temperature may result in a delay of the coatingcomponent crystallizing onto the surface of the core pellet which maylead to loss of the coating component from the core pellet or unevendistribution of the coating component either upon the individual corepellets or among the individual core pellets. Too low of a temperatureof the core pellets may cause the higher melting point temperaturecomponent droplets to immediately crystallize on touching the surface ofthe core pellets.

In one embodiment, the coating component contacts the surface of thecore pellet as a liquid and remains liquid for a brief period of time toallow the coating component to spread among the core pellets throughsurface contact among the core pellets as the core pellets are mixed inthe fluidizing mixer. In one embodiment, the coating component remains aliquid for a time period from 1 second to 15 seconds. Without beingbound by theory, it is believed that if the temperature of the corepellets or the higher melting point temperature component is too lowthat it would cause the higher melting point temperature component tosolidify too soon in the manufacturing process. It is believed that itis the early solidification of the higher melting point temperaturecomponent that leads to difficulties such as agglomeration, stickiness,and uneven coating.

In one embodiment, the temperature of the core pellets at the start ofthe coating process will be at ambient temperature or above ambienttemperature. A process may provide the core pellets at ambient orgreater than ambient temperature. Coatings that do not derive anadvantage from cooling the core pellets for reasons of crystallizationor viscosity increase may derive an advantage with using the corepellets directly as provided to the mixer and not cooling the corepellets.

In one embodiment, the core pellets and the coating component can beintroduced into the paddle mixer at separate times but at substantiallyidentical physical locations. In one embodiment, the core pellets andthe coating can be introduced into the paddle mixer at the same time andsubstantially identical physical locations. In one embodiment, the corepellets and the coating can be introduced into the paddle mixer atseparate times and at separate locations. In one embodiment, the corepellets and the coating can be introduced into the paddle mixer at thesame time and separate locations. In one embodiment, the core pelletscan be added to the mixer, the mixer is started, and fluidization of thekibbles begins. The kibbles can be optionally further cooled byintroducing a stream of cold air or gas such as carbon dioxide. Thecoating can then be added down the side of the mixer. By introducing thematerial to be coated down the side of the mixer, the material can beswept down with the descending core flow across the bottom of the mixerthen up into the fluidized zone with the core, where all of it can becoated. When the coating is added down the side(s), it not only getsswept down with the core flow, then up towards the center, it also canbe intimately mixed and dispersed with the cores. The cores are not onlygetting swept down, then up and around, but at the same time they aremoving around the mixer from side to side.

In one embodiment, the coating process may have an average core pelletresidence time in the dual-axis paddle mixer of from 0 minutes to 20minutes. In one embodiment, the core pellet residence time in thedual-axis paddle mixer may be from 0.2, 0.4, 0.5, or 0.75 minutes to 1,1.5, 2, 1.5, or 3 minutes.

The Froude number of the mixer, whether batch or continuous, can begreater than 0.5, or even greater than 1.0, during operation of forminga coated kibble. The Froude number is defined as a dimensionless number(Fr)=(V²/Rg) and relates inertial forces to those of gravity; R is thelength of the paddle from the centerline of the axle to the tip of thepaddle (cm), V is the tip speed of the paddle (cm/sec), and g is thegravitational constant. The Froude number is a dimensionless numbercomparing inertial forces and gravitational forces. The inertial forcesare the centrifugal forces that are mixing the cores and coatings. Nomaterial properties are accounted for in the Froude number. When theFroude number is greater than about 1, the centrifugal forces hurlingthe cores and other material up in the center are greater than thegravitational forces pulling them back down. Thus, the kibbles arebriefly suspended in air. In this state, materials such as coatingmaterials can move freely around, and onto, the core, thus ensuringclose to even, and including even, coating. In one embodiment, if theFroude number is too high, the kibble may be thrown against the topand/or the sides of the mixer with such force as to crack, chip, orbreak the kibbles, or, if the top of the mixer is open, the kibbles maybe ejected from the mixer entirely. In one embodiment, the Froude numbercan be above about 0.5 and below about 3.

If the binder component is added separately over the top of thefluidized zone of the mixer, and the protein component is addedseparately below the fluidized zone, it may be effective to split theprotein components into two streams and introduce the streams atopposite corners of the mixer, one on either side of the binder additionzone whereby the protein component(s) travel downward along the side orsides of the mixer, preferably the sides parallel to the paddles axles.Material is swept downward to the bottom of the mixer and then is sweptback upward into the converging flow zone of the counter-rotating paddleaxes.

Without being limited by theory, it is believed that this sets up twoconvective loops of protein components circulating in the mixer, one oneither side of the binder addition zone. A single complete circuit ofthe protein components through a convective loop is referred to as theconvective cycle time. It is believed that holding the convective cycletime constant regardless of the size of the mixer can achieve a similardistribution of the coating over the surface of the core pelletsregardless of the size of the mixer.

It may often be convenient to include more than one binder componentspray zone on the top of the fluidized zone in order to improve theevenness of the coating. Each binder addition zone may include twoprotein addition points, one on either side of the individual sprayzone. The protein addition points can be below the fluidized zone, andthe binder addition points can be above the fluidized zone of the mixer.Thus, two separate binder addition points above the fluidized zone ofthe mixer can include four separate binder addition points below thefluidized zone.

The binder flux is defined as the amount of binder component in gramsthat passes downward though a given area on the top of the fluidizedzone. The coating addition flux is defined as the amount of coatingcomponent in grams through the same given area upward through thefluidized zone. The dimensionless flux is defined as the binder fluxdivided by the coating flux and the number of convective loops in themixer. While not being limited by theory, it is believed that holdingthe dimensionless flux constant regardless of the size of the mixer canhelp achieve a similar distribution of the coating over the surface ofthe core pellets regardless of the size of the mixer.

If a water-based binder is used to apply the coating, or if the producthas had steam applied after the coating step as described herein, it maybe desirable to dry the product in one embodiment. Drying can beaccomplished by any of the methods described herein. The exactconditions of the drying will depend on the type of dryer used, theamount of moisture, or water, removed, the temperature sensitivity ofthe applied coating, and the final moisture, or water, level of theproduct required. One skilled in the art would be able to adjust thesefactors appropriately to achieve the desired product. Additionally,drying can be performed in the mixer where the coating took place. Astream of dry air at a temperature elevated above ambient can be passedover the product at a sufficient rate to remove the amount of moisture,or water, required over the time period required. In one embodiment,using a fluidized mixer, the air can be directed on top of the product,directly over the center of the fluidized zone, while the product isbeing agitated. In one embodiment, the air can be directed down one orboth sides of the mixer so that the flow of the air is the forced upwardthrough the fluidized zone. In one embodiment, the air can be introducedinto the mixer by means of manifolds on the inside walls of the mixer.In one embodiment, the air can be introduced into the mixer by means ofa manifold at the bottom of the mixer, below the fluidized zone. Oneskilled in the art would be able to adjust the mixer agitation rate tocompensate for any effects on the fluidized behavior of the product bythe introduction of air flow.

In one embodiment the fluidizing mixer can be a continuous fluidizingmixer. Many commercial processes are continuous flow processes. Acontinuous process can have the advantages of a lower cost and greateroperating efficiency than a batch process, especially as the amount ofmaterial being processed increases. The core material may becontinuously introduced into the mixer at one end of the mixer. The massflow of the cores combined with the angle on the paddle blades cause thekibbles to move through the bed to the other end of the mixer, wherethey continuously exit the mixer. The continuous flow of kibble into themixer and the continuous flow of the kibbles out of the mixer areadjusted so that the flows are mass balanced and steady state, and theamount of kibble at any one time inside the mixer is approximatelyconstant. The paddles are at an angle such that the kibbles arefluidized, yet maintain a forward flow through the mixer. In a batchfluidizing mixer, the paddles are angled so that the cores are fluidizedin the converging zone, and at the same time there is a convective flowof the cores in a circular pattern around the perimeter of the mixer.Unlike the batch fluidized bed mixer, the paddles for the continuousfluidized bed mixer are angled so that the core materials flow along thelength of the mixer parallel to both axles. In one embodiment, therotation of the paddles can be counter-rotating such that the paddlescause the core materials to have an upward convective flow of corematerial in or near the center of the mixer and a downward convectiveflow along the sides of the mixer. In another embodiment, the rotationof the paddles can be counter-rotating such that the paddles cause thecore materials to have a downward convective flow of core material in ornear the center of the mixer and an upward convective flow along thesides of the mixer. The angle of the paddles should be adjusted so thatthere is proper upward and downward convective flow and the corematerials are fluidized in the center. The angle of the paddles shouldalso be adjusted so that the core materials remain in the mixer for thedesired amount of time for substantially even coating. In oneembodiment, the continuous mixer can be operated so that the Froudenumber is between about 0.8 and about 3, or from about 0.8 and about 2,or from about 0.8 to about 1.2, or about 1.

It is desirable that the flow of the core material through thecontinuous mixer be substantially plug flow. Plug flow is defined as theminimization of axial mixing. Axial mixing is defined as the tendency ofan aliquot of core materials to spread away from one another in thedirection of the mass flow of the core material. When flow of the corematerial is substantially plug flow, the core materials are in the mixerfor approximately the same amount of time. With increasing axial mixing,the times that the cores spend in the mixer can vary somewhat, possiblyresulting in more uneven coating from core particle to another. Theamount of axial mixing in a mixer can be calculated according to amethod described in Levenspiel in “Chemical Reaction Engineering”. ThePeclet number is a measurement of the amount of axial mixing and degreeof plug flow. The Peclet number is a dimensionless number that is theratio of the axial mixing along the length of the mixer in the directionof core material flow to the bulk flow of the core material. The largerthe Peclet number, the better the plug flow. Higher Peclet numbers mayresult in more even coating of the core material. In one embodiment, themixer can be operated so that the Peclet number is greater than about 6.In one embodiment the mixer is operated so that the Peclet number isgreater than about 40. In one embodiment the mixer is operated so thatthe Peclet number is greater than about 100. A suitable counter-rotatingdual-axle paddle mixer may be obtained from Hayes & Stolz, Ft. WorthTex.

In one embodiment, the angle of the paddles in the continuous paddlemixer is adjusted so that when the kibbles are flowing through it, theFoude number is between about 0.8 and about 1.2 and the Peclet number isgreater than about 6.

In one embodiment the coating may be applied to the kibble over thefluidizing zone in the continuous mixer. In one embodiment, the liquidbinder may be sprayed onto the kibble above the fluidizing zone. In oneembodiment, the liquid binder may be sprayed over the fluidizing zone inone or more locations along the length of the mixer. In one embodiment,the coating material may be applied to the kibble over the fluidizingzone of the continuous mixer. In one embodiment, the coating materialmay be applied over the fluidizing zone in one or more locations alongthe length of the continuous mixer. In one embodiment, the coatingmaterial may be added to the mixer with the kibble stream at thebeginning of the continuous mixer.

In one embodiment, the average residence time of the core materialsinside the coating unit is from about 10 to about 600 seconds. In oneembodiment, the average residence time of the core materials inside thecoating unit is from about 30 to about 180 seconds. When the averageresidence times of the core materials in the coating unit are in thisrange, the core materials may be coated substantially evenly, whilekeeping the size of the equipment compact.

In one embodiment, the flow of core materials though the unit should befrom about 10 to about 60,000 kilograms per hours (kg/hr). In oneembodiment, the flow of core materials though the unit should be fromabout 1000 to about 40,000 kg/hr.

Salmonella Deactivation Steps

Additional embodiments of the present invention include a method ofmaking a pet food including at least one heat treating Salmonelladeactivation step. The pet food can be in any form of embodiments of thepet food described hereinabove, and it can also include any other petfood. In one embodiment, a non-limiting example of which is a coatedkibble that comprises a core and a coating as hereinabove described, twoheat treating deactivation steps can be performed. The core can beformed through extruding, as described hereinabove. After extruding intoa core, the core can be heat treated in a manner to sufficientlydeactivate any Salmonella present in the core. Subsequently, prior to,or contemporaneously with, the coating can be formed and heat treated ina similar manner as that of the core to deactivate any Salmonellapresent. The coated kibble can then be formed, as described hereinabove,by coating the core with the coating.

Salmonella generally require the application of heat while the microbesare in a moist environment. Once completely dry, Salmonella can becomedormant and resist efforts using dry heat to deactivate them. In a moistenvironment, Salmonella are more readily deactivated. For example, theapplication of heat at 80° C. for greater than about two minutes caneffectively deactivate Salmonella when in a moist environment.Application of temperatures higher than 80° C. in moist environmentsresults in correspondingly shorter times needed to deactivate theSalmonella.

Superheated steam has been used effectively in many industries todeactivate Salmonella. Superheated steam is defined as steam at atemperature greater than the boiling point of water for the existingpressure. Most industrial use of superheated steam utilizes pure orsubstantially pure steam. The non-steam component is usually air.

It has additionally been found that Salmonella can be effectivelydeactivated with humid hot air, at ambient pressure, at temperaturesgreater than about 80° C. One advantage of this method is that humid hotair can be injected into the fluidizing mixer at ambient pressureconditions during or after the coating step. The temperature of thehumid hot air can be greater than 80° C. Higher temperatures can resultin shorter times of application of humid hot air to effectivelydeactivate Salmonella. The relative humidity of the air can be greaterthan 50% and can even be greater than 90%. Relative humidity is definedas the ratio of the partial pressure of water vapor in the air to thesaturated vapor pressure of water at a given temperature.

Thus, in one embodiment, hot air at greater than 80° C. and up to 200°C. is blown into the top of the mixer where a coated kibble has beenformed. The air can be blown at about 0 to 80 CFM. Once the hot airstarts blowing into the mixer, steam at a pressure of 0 to 30 PSIG andat a rate of about 0 to 4 kg/min can be injected into the mixer for 0 toabout 2 minutes. The combination to hot air and steam in the mixerresults in a hot air stream that can reach about 95% relative humidity.At the end of from 0 to 2 minutes, the steam can be stopped but the hotair can be continued for up to additional 8 minutes. During this period,the relative humidity inside the mixer drops, and, as it drops,moisture, or water, is removed from the surface of the kibble. At theend of the cycle of hot air, the Salmonella will be sufficientlydeactivated.

An additional method of heat treating, or deactivating, Salmonella ofthe pet food in accordance with one embodiment of the present inventionis disclosed in RU 2251364.

Vitamin Stability

It has been found that a coated kibble and processes of making thereofin accordance with embodiments of the present invention can allow forthe coating of the kibble with temperature, pressure, and moisturesensitive ingredients, including all of the ingredients, sources, andcomponents described herein. In one embodiment, the sensitiveingredients bypass the normally stressful conditions of extrusionprocesses and conditions as are customarily used in the art.

Additionally, it has been found that a coated kibble according toembodiments of the present invention can enhance vitamin deliverystability as well as reduce cost savings due to loss of vitamins duringnormal, heretofore used extrusion processes.

Embodiments of the present invention are related to providing, ordelivering, sensitive ingredients. Non-limiting examples of sensitiveingredients include the other ingredients as described herein, includingthe active ingredients described herein, which include vitamins.Sensitive ingredients are those which are generally thought of astemperature, moisture, and pressure sensitive, such that certainconditions of temperature, moisture, and pressure can negatively impactthe efficacy of the sensitive ingredient, including by increasing lossof the sensitive ingredient during processing or during storage. Thus,bypassing the normal stressful conditions of an extrusion process bybeing added to the core kibble after the core is extruded can beadvantageous for sensitive ingredients. Thus, in one embodiment, thecore kibble of any of the embodiments disclosed herein can be late-stagedifferentiated with sensitive ingredients, including vitamins, asdescribed herein. Vitamins can be highly susceptible to oxidativeconditions of extrusion, necessitating over formulation of vitaminpre-mix before entering the extrusion process to ensure appropriatelevels of vitamins at the time of consumption by the pet. Coating thevitamins in a fluidized mixer as disclosed herein would not expose thevitamins to harsh conditions and could maintain the physical andchemical integrity of the vitamin and any stabilizers. As a result, thevitamin retention in the process increases, and the stability in storagecan improve. As used herein, vitamin component includes vitamins andvitamin premixes.

Thus, one embodiment of the present invention includes a process ofdecreasing processing loss of vitamins of a pet food in the form of acoated kibble, such that vitamin retention can be improved. Whenkibbles, or cores, are extruded with vitamins, vitamin loss can beconsidered at its peak. Upwards of 30% to 40% of the vitamins added tothe core prior to extrusion can be lost during the extrusion process. Insome instances, up to 36% of vitamin A can be loss during extrusion, andabout 11.2% of vitamin E can be loss during extrusion. However, in oneembodiment of the present invention, the core can be extruded asdescribed herein, wherein the core is comprised substantially free ofvitamins prior to extrusion. After the core has been extruded inaccordance with embodiments of the present invention, sensitiveingredients, such as any of the vitamins disclosed herein, non-limitingexamples of which can be vitamin A and vitamin B, can be coated onto theextruded core, using a fluidizing mixer, non-limiting examples which aredisclosed herein. The coating can be any of the coatings as describedherein. In one embodiment, the coating can comprise vitamin A, vitaminE, a fat component, a palatant component, and any combinations andmixtures thereof. During the coating process, vitamin loss can also bepresent, however, according to embodiments of the present invention,vitamin loss can be decreased versus when the vitamin is extruded withthe core. In one embodiment, vitamin loss during coating can be lessthan 10%. Other embodiments include vitamin processing loss of less than9%, less than 8%, less than 7%, less than 6%, less than 5%, less than4%, and less than 3%. In one embodiment, the vitamin loss of vitamin Acan be less than 9%. In another embodiment, vitamin loss of vitamin Ecan be less than 4%.

Additionally, another embodiment of the present invention includes amethod, or process, of improving the stability of vitamins during andafter storage of a pet food in the form of a coated kibble. Thus, anembodiment of the present invention comprising a coated kibble, whereinthe coating comprises a fat component and a binder component, canimprove, or increase, the stability of vitamins. In one embodiment, thetotal retention of vitamin A, after the processing of the kibble andafter 16 week storage can be at least 50%. In another embodiment, thetotal retention of vitamin A can be at least 55%. In another embodiment,the total retention of vitamin A can be at least 60%. In anotherembodiment, the total retention of vitamin A after processing of thekibble can be at least 61%.

In another embodiment, the total retention of vitamin A after processingof the kibble can be at least 61%. In another embodiment, the totalretention of vitamin A after processing of the kibble can be at least60%. In another embodiment, the total retention of vitamin A afterprocessing of the kibble can be at least 55%. In another embodiment, thetotal retention of vitamin A after processing of the kibble can be atleast 50%.

One embodiment can include a coating comprising a beadlet homogenized.In this embodiment, the coating can comprise a binder component and avitamin component. The binder component can be a solution that ishomogenized with the vitamin component. The mixture can be homogenizedwith a high sheer mixer to decrease the particle size of the beadlet inorder to better adhere it to the surface of the kibble.

Another embodiment can be a coated beadlet. This embodiment can be madeby spraying the binder component solution on the kibbles for about 10seconds and then adding the vitamin component to the mixer while stillspraying the binder solution over an additional 45 seconds.

Another embodiment can be a coating in the form of a powder. Thisembodiment can be made by adding a water soluble form of the vitamincomponent to the binder solution and then coating the solution over thekibbles. The powder form can comprise the vitamin component in a starchmatrix.

In these embodiments, the vitamin component can be less than 1% of thecoated kibble, even less than 0.5%, and even less than 0.2% of thecoated kibble. The vitamin component can be a vitamin premix, which caninclude a carrier. In one embodiment, the vitamin component can be up to0.3%.

Additionally, as is noted in the Examples that follow, the addition ofvitamins in accordance with embodiments of the present invention resultsin increased animal preference. It is well known in the art that theaddition of vitamins to pet food usually results in a decrease in animalpreference. However, embodiments of the present invention whereinvitamins are added to a pet food results in an increase in animalpreference. Thus, one embodiment of the present invention comprises acoated kibble, wherein the coating comprises vitamins, and wherein theanimal preference of the coated kibble is greater than the animalpreference of a kibble with vitamins that is not coated in accordancewith coating embodiments of the present invention.

When describing the processing of coated kibbles in view of improvingvitamin retention and stability, it should be understood that any of theprocessing steps, methods, and parameters as disclosed anywhere hereincan be applied to the process of improving vitamin retention andstability.

Oxidation

It has been found that the stability, or lack of oxidation, of thecoated kibble made in accordance with embodiments of the presentinvention can be increased. In one embodiment, the layering or coatingas disclosed herein of the solids ingredients decreases the amount offat ingredient of the coating that migrates, or wicks, into the core,which is where catalysts for oxidation can be present. In oneembodiment, a non-limiting example of an oxidation catalyst is iron,which can be present in the core. The coating can comprise a proteincomponent, a non-limiting example of which is chicken by-product meal,and a layer of a fat component. The protein component can decrease theamount of fat component that reaches the core and thus can reduce theamount of oxidation that occurs by way of the iron acting as anoxidative catalyst. The total aldehydes is a measure of the aldehydesthat are formed in a food product. Aldehydes form as a result of foodfatty acids that contain double bonds being converted to aldehydesbecause of their exposure to oxygen. Thus, less oxidation results inless aldehyde formation, which can mean less rancidity. Additionally, anOxygen Bomb may be used to provide an approximate measure of length ofoxidation absorbing capacity of the antioxidants in a food product. Thehigher the value, the longer a product is expected to be stable.

Thus, in one embodiment, a coated kibble having less aldehyde formationthan other kibbles is disclosed. The coated kibble can have a coatingcomprising a fat component, a protein component, and a binder component.The coated kibble can have less aldehyde formation than a core withoutthe coating. The coated kibble can have less aldehyde formation than acore having a fat component and/or palatant component, but no proteincomponent.

Two comparisons are represented in FIG. 2 and FIG. 3. Uncoated Iams®Mini-Chunks core kibble can be considered oxidatively unstable as notedby the high Total Aldehydes (TA) level shown in FIG. 2. This graphillustrates the product stability benefit provided by mixed tocopherolsadded through the poultry fat. When Iams® Mini-Chunks current or chickenby-product meal layered kibbles are coated with an amount of fat at 5%,total aldehydes are less than 60 ppm. Comparatively, chicken mealby-product layering does not appear to result in greater total aldehydesthan current Iams® Mini-Chunks. As total aldehydes increase in samples,human sensory begins to identify those samples as rancid. The oxygenbomb comparisons are shown in FIG. 3. As can be seen, the chicken mealprototype had increased oxygen bomb levels when compared to an uncoatedcore and an Iams® Mini-Chunks kibble. This result correlates to anincrease in stability and thus shelf life of the product.

Thus, FIGS. 2 and 3 show that embodiments of the present invention,including a coated kibble having coating comprising chicken by-productmeal, increases the coated kibbles oxidative stability in that totalaldehydes decreases while the oxygen bomb increases.

Coated Kibble Properties

As described hereinabove, at least one advantage of the coated kibble inaccordance with embodiments of the present invention includes anincrease in animal preference, or pet acceptance or preference. Thus,coated kibbles according to embodiments disclosed herein are preferredby pets based on animal preference tests as described herein. Thus, asdisclosed in the Examples that follow, an increase in animal preferencecan be present with coated kibbles in accordance with embodiments of thepresent invention. It is thought, without being limited by theory, thatthe increase in animal preference, or pet acceptance, can be explainedby the following characteristics of the coated kibble, includingmixtures and combinations of these. Thus, it should be understood thatcoated kibbles in accordance with embodiments of the present inventioncan include any of the following properties, all of the followingproperties, and any mixtures and combinations of these properties.Additionally, the coated kibbles can be nutritionally balanced, asdescribed herein.

Wicking of Fat/Palatant

In one embodiment, a coated kibble can comprise a core and a coatingwherein the coating can comprise a protein component comprising achicken by-product meal, wherein the chicken by-product meal coating cancomprise the outermost coating of the kibble, such that it is exposed tothe environment and thus the animal upon eating. In one embodiment ofthe present invention, the increase in animal preference response(PREF), or animal acceptance or preference, can be correlated to anincrease in relative fat level on the kibble surface. Animal preferenceresponse, which can be tested using a split plate test response, PREFtest, includes ratio percent converted intake or ratio first bite.Without being limited by theory, it is thought that, in one embodiment,the increased animal preference response results because the proteincomponent of the coating, such as those protein components describedherein, a non-limiting example of which is chicken by-product meal, thatis layered on the core prevents, or decreases, the wicking of fatcomponents and/or palatant components that can also be part of thecoating layered onto the kibble. Thus, one embodiment of the presentinvention relates to a method to prevent, or decrease of the amount ofwicking of fat components and/or palatant components from the coating ofa kibble into the core of the kibble. Additionally, the decrease orprevention of wicking of fat components and/or palatant components isthought to contribute to the improved animal preference response becausemore of the fat components and/or palatant components remain on theexposed surface of the kibble. Thus, one embodiment of the presentinvention relates to a pet food, and a method of providing a pet food,comprising an animal preference enhancing amount of fat on the kibblesurface. As used herein, animal preference enhancing amount means anamount that increases the animal preference response, whether ratiopercent converted intake or ratio first bite, or both of these.Additionally, while increased amounts of fat components and/or palatantcomponents can be simply added to the exterior of pet foods, thoseincreased amounts would modify the nutritional profile of the pet food,resulting in an unbalanced pet food. Thus, in one embodiment of thepresent invention, the pet food can be a balanced pet food, such as acoated kibble.

In one non-limiting example of one embodiment of the present invention,as illustrated in FIG. 1, a coated kibble 100 comprises a core 101. Afirst coating 102 can be layered onto core 101 as an inner coating. Asecond coating 103 can be layered onto first coating 102 and be an outercoating. First coating 102 can comprise a binder component and a solidscomponent, such as a protein component, and combinations and mixtures ofthese. Non-limiting examples of the binder component can be as describedherein and can include whey protein isolate or chicken broth.Non-limiting examples of the solids component can be as described hereinand can include chicken by-product meal. Second coating 103 can comprisea fat component and a palatant component, and combinations and mixturesof these. Non-limiting examples of the fat component can be as describedherein and can include chicken fat. Non-limiting examples of thepalatant can be as described herein and can include chicken liverdigest.

Thus, as shown in FIG. 1, the first coating 102 can act as a barrierlayer to second coating 103 in that first coating 102 reduces thenatural migration or wicking of the components of second coating 103from the outer coating to the inner coating and further into the core.Thus, more of the initial amount of the second coating that was coatedonto the kibble remains on the outer coating of the coated kibble. It isthought that since the first coating can comprise solid components, suchas chicken by-product meal as disclosed herein, that this solidcomponent keeps the normally moist second coating, which can comprisefat components and/or palatant components, from migrating, or wicking,from the outer coating into the inner coating and/or the core of thecoated kibble.

It should be understood, however, that the binder component, solidscomponent, fat component, palatant component, and any other componentsas used herein, can applied, or coated, in any order and using anycoating procedure. Thus, the solids component, the binder component, thefat component, and the palatant component can be applied in any order.

Thus, in one embodiment, a coated kibble, a method of providing a coatedkibble, and a process for making a coated kibble, comprising a solidbarrier layer is disclosed. The solid barrier layer can be applied to acore and can comprise a protein component, which can include chickenby-product meal, and a binder component, in one non-limiting example.The outer layer can then be applied and can comprise a fat component anda palatant component. In one embodiment, the barrier layer of a solidscomponent and a binder component can decrease the migration, or wicking,of the fat component and/or palatant component.

Aroma

Layering of a protein component, or any of the other components asdescribed herein, as a coating on a core, as described herein, can alsoalter the aroma profile of a coated kibble and result in a coated kibblehaving different aroma profiles than typical pet food. Certainembodiments of coated kibbles as disclosed herein may contain specificcompounds and components that can give the pet food desirable aromas.These compounds and components can cause changes in the aroma profile,or aroma attribute changes, which can result in improved animalpreference, or animal acceptance or preference, using embodiments of acoated kibble as disclosed herein. Without being bound by theory, it isthought that these aroma attribute changes contribute to the improvedpreference results as detailed herein, and as shown in Tables 1, 2, and3, of a coated kibble wherein the coating comprises a protein component,a non-limiting example such as chicken by-product meal, layered onto akibble core. Previous consumer research has suggested that human-likearomas on pet food could be perceived as improvements in products.Examples hereinafter help to describe and show the changes in aromaprofile or character that accompany non-limiting examples of embodimentsof the present invention.

Thus, one non-limiting example of an embodiment of the present inventionrelates to a coated kibble, and a method of delivering a coated kibble,having an aroma profile, an analyte concentration, and an aromacorrelation, wherein the aroma correlation relates the aroma profilecomprising an analyte concentration to the increase in animalpreference. Additionally, another embodiment relates to a coated kibblehaving an aroma profile, an analyte concentration, and thus an aromacorrelation. With these embodiments, animal preference (PREF) responsedata, or animal acceptance or preference, can be correlated with thearoma profile and analyte concentration, as disclosed herein. Thus, inone embodiment, aroma analyte profiles and concentrations can correlateto positive, or increased, animal preference response data.Additionally, in one embodiment, the coated kibble comprises an animalpreference enhancing amount of an analyte. The animal preferenceenhancing amount of the analyte can be within the coating, within thecore, and combinations and mixtures of these. In another embodiment, amethod of enhancing the animal preference of a pet food comprisesdelivering an animal preference enhancing amount of an analyte in a petfood is disclosed. As used herein, animal preference enhancing amountmeans an amount that increases the animal preference response, whetherratio percent converted intake or ratio first bite, or both of these.

The aroma profile, including analyte concentration, can be determined inaccordance with the method as disclosed hereinafter, using Solid PhaseMicroExtraction Gas Chromatography/Mass Spectrometry (SPME-GC-MS) toanalyze pet food samples for compounds associated with the aroma. Thearea under the curve was measured as the SPME analysis number or count.

One embodiment of the present invention relates to a coated kibble and amethod of delivery thereof wherein the coated kibble has a particulararoma profile. A non-limiting example of a coated kibble comprises acore comprising a carbohydrate source, a protein source, a fat source,and other ingredients, all as disclosed herein, and a coating comprisinga protein component, a binder component, a palatant component, a fatcomponent, and other components. In this embodiment, an aroma profile ofthe coated kibble can be generated and analyzed showing the effect ofspecific analyte concentrations on the aroma. Concentrations can bedetermined for each of the analytes. The concentration of the analytescan then be correlated with PREF response data that was gathered foreach of the embodiments to show an aroma correlation with the PREFresponse data. Thus, in one embodiment, an increase in particularanalytes present in the aroma can drive up, or increase the PREFresponse data, meaning a greater PREF response, resulting in higheranimal preference or acceptance.

In one embodiment, the analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these, can be elevated or representative of familieswith elevated levels when compared to off the shelf pet food. Thus, inone embodiment, a coated kibble comprising particular concentrations ofthe analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these, increases PREF response. Thus, an animalpreference enhancing amount of the analytes 2-piperidione,2,3-pentanedione, 2-ethyl-3,5-dimethypyrazine, furfural, sulfurol,indole, and mixtures and combinations of these, can be present in oneembodiment of the coated kibble. This animal preference enhancing amountof the analytes can increase the PREF response. In one embodiment, theRatio Percent Converted Intake (PCI) can increase with an animalpreference enhancing amount of the analytes 2-piperidione,2,3-pentanedione, 2-ethyl-3,5-dimethypyrazine, furfural, sulfurol,indole, and mixtures and combinations of these. In another embodiment,the Ratio First Bite can increase with an animal preference enhancingamount of the analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these.

Thus, one embodiment of the present invention relates to a coated kibblecomprising an enriched amount, or an animal preference enhancing amount,of the analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these. Another embodiment includes a method ofdelivering a coated kibble comprising an animal preference enhancingamount of the analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these.

Another embodiment of the present invention relates to a method ofenhancing the animal preference of a pet food comprising delivering ananimal preference enhancing amount of an analyte in a pet food. Themethod can include providing a pet food, as disclosed herein, whereinthe pet food comprises enriched amount, or an animal preferenceenhancing amount, of the analytes 2-piperidione, 2,3-pentanedione,2-ethyl-3,5-dimethypyrazine, furfural, sulfurol, indole, and mixturesand combinations of these. The method can also comprise adding to petfood animal preference enhancing amounts of the analytes 2-Piperidione,2,3 pentanedione, 2-ethyl-3,5-dimethypyrazine, furfural, sulfurol,indole, and mixtures and combinations of these.

In one embodiment, the analyte 2-piperidione can have a SPME analysisnumber of greater than 1,500,000, or less than 10,000,000, or between1,500,00 and 10,000,000, and all integer values less than, greater than,and therebetween those values. In one embodiment, the analyte2,3-pentanedione can have a SPME analysis number of greater than 65,000,or less than 500,000, or between 65,000 and 500,000, and all integervalues less than, greater than, and therebetween those values. In oneembodiment, the analyte 2-ethyl-3,5-dimethypyrazine can have a SPMEanalysis number of greater than 310,000, or less than 1,000,000, orbetween 310,000 and 1,000,000, and all integer values less than, greaterthan, and therebetween those values. In one embodiment, the analytefurfural can have a SPME analysis number of greater than 2,300,000, orless than 7,000,000, or between 2,300,000 and 7,000,000, and all valuesless than, greater than, and therebetween those values. In oneembodiment, the analyte sulfurol can have a SPME analysis number ofgreater than 150,000, or less than 1,000,000, or between 150,000 and1,000,000, and all values less than, greater than, and therebetweenthose values. In one embodiment, the analyte indole can have a SPMEanalysis number of greater than 176,000, or less than 2,000,000, orbetween 176,000 and 2,000,000, and all values less than, greater than,and therebetween those values. In another embodiment, the coated kibblecan comprise mixtures and combinations of these analyte SPME analysisnumbers, including just one of these.

As described herein, an animal preference enhancing amount of theseanalytes, either alone or in a combination or mixture, can increase theanimal preference response, whether ratio percent converted intake orratio first bite, or both of these. For example, Example 3 hereinaftershows just two non-limiting examples of the present invention, namely afirst prototype of a chicken by-product meal layered kibble made byenrobing a formula re-balanced Iams® Mini-Chunks core kibble with 10%chicken by-product meal and 5% chicken broth (20% chicken brothsolution), all by weight of the kibble, with a palatant system of 1%chicken liver digest and 2% chicken viscera digest added along with 5%fat, and second prototype made similarly to the first prototype with theexception that it utilized a different binder, 5% whey protein isolate(20% whey protein isolate solution), and did not include any chickenviscera digest. As shown in Table 3, with Test 1 for the first prototypeand Test 2 for the second prototype, the percent converted intake andthe first bite are both at ratios consistent with an increase of animalpreference response. Specifically for the first prototype, a percentconverted intake ratio of 16.5:1 and an infinite first bite werepresent. Specifically for the second prototype, a percent convertedintake ratio of 16.2:1 and 31:1 first bite were present. Thus, an animalpreference enhancing amount of one, all, or a mixture or combination ofthe analytes can be present and is evidenced by these increase animalpreference responses.

Additionally, and as described hereinafter in Example 4 and as shown inFIGS. 4 through 6, consumer data illustrates aroma profile differencesbetween non-limiting embodiments of the present invention and commercialpet food that is not enriched with the aroma analytes as describedherein. FIG. 4 shows the panel's aroma characterization for Iams®Mini-Chunks. As can be seen, Mini-Chunks is reduced in OverallIntensity, Yeast, and Dirty Socks aroma character. FIG. 5 shows thechicken by-product meal protein layering prototype of Example 2 with noadditional palatant. The chicken by-product meal protein layeringprototype results in increased Oily/Fatty and Overall Meaty character.FIG. 6 shows the chicken by-product meal layering prototypes with theaddition of palatant(s) of Example 3, Tests 1 and 2. The chickenby-product meal protein layering prototype results in increasedOily/Fatty character but had a similar Overall Meaty character. Chickencharacter was also elevated for the chicken by-product meal layeringprototype with additional palatant.

Additionally, consumer research has suggested that certain aromas on petfood could be perceived as improvements in pet food products, such askibbles, from a human perspective. Thus, non-limiting examples ofembodiments of the present invention provide an aroma profile thatprovides certain increased and decreased aroma attributes perceived byhumans. Aroma attributes can include the following: overall intensity,oily/fatty, overall meaty, chicken, fish, yeast, toast, sweet, dirtysocks, cardboard, earthy, grainy, and beefy. In some embodiments it canbe desired that certain of these aroma attributes are at increased, orhigher, levels while certain of these attributes are at decreased, orlower, levels. Thus, in one embodiment of the present invention, a petfood in accordance with any of the embodiments described herein isprovided such that an aroma profile is provided by the pet food that isperceptible to humans, wherein the aroma profile can be described usinghuman sensory aroma attributes. Embodiments of the human sensoryattributes include elevated levels of oily/fatty aroma, elevated levelsof overall intensity, elevated levels of overall meaty aroma, decreasedlevels of cardboard aroma, decreased levels of dirty socks aroma, andcombinations and mixtures of these.

Examples Example 1—Animal Preference

Test #1: Kenneled dogs were tested using the following kibbles. Akibbled dog food was made as a test kibble prototype using the core ofIams® Mini-Chunks. The core was coated with a layer of 0.5% chickenliver digest, 2% fat, 10% chicken by-product meal, and 5% chicken broth(as a binder, 20% chicken broth solution), all by weight of the kibble.A control prototype was made using the core of Iams® Mini-Chunks andcoated with 0.5% chicken liver digest and 2% fat, all by weight of thekibble.

Test #2: In-home pet dogs were tested using the following kibbles. Atest kibble prototype was made using the core of Iams® Mini-Chunks. Thecore was coated with a layer of 0.5% chicken liver digest, 2% fat, 10%chicken by-product meal, 5% chicken broth (as a binder, 20% chickenbroth solution), all by weight of the kibble, and was coated with a0.13% vitamin pre-mix to determine whether externally coating vitaminson a core having a protein layer would negatively impact animalpreference of the kibble. A control prototype was made using Iams®Mini-Chunks as a core and coated with 0.5% chicken liver digest and 2%fat, all by weight of the kibble.

Both tests included a Salmonella inactivation step of adding 4%moisture, or water, to the chicken by-product meal layer then drying theproduct for three minutes at 260° F.

Test #1 resulted in the chicken by-product meal layered prototype beingoverwhelming preferred by dogs (41:1 total volume; 50:1 PercentConverted Intake (PCI); See Table 1 below). Moreover, over 98% of thetotal food consumed during the two day split plate test was the chickenby-product meal layered prototype. Test #2 resulted in the chickenby-product meal layered prototype being preferred by in-home dogs (4.5:1total volume; 4.4:1 PCI). To put these results into perspective, beforedogs (or cats) are allowed to be on an animal preference panel, theyundergo qualifying PREF tests. One of the qualifying tests typically isan obvious choice (known positive control versus a known negativecontrol). The positive control typically is made with the normalcommercial palatant, such as chicken liver digest, coated onto it. Thenegative control is made without a palatant. A previous “obvious choice”test with the kenneled dogs resulted in 16:1 total volume; 14:1 PCI. Aprevious “obvious choice” test with in home dogs resulted in a 2.2:1total volume; 2.4:1 PCI. In neither case, kenneled or in home pets, didthe obvious choice test result in as strong of a preference as occurredwith the chicken by-product meal layered prototypes.

TABLE 1 Summary Results of Preference Tests Compared to Reference TestsReference Test 1 Reference Test 2 Test 1 Test 2 Test (Kenneled Dogs Test(In Home Pets Test (Chicken by-product Test (Chicken by- product Obviouschoice - Obvious choice - meal Layered Prototype) meal LayeredPrototype) with Palatant) with Palatant) Results vs. Control vs. Controlvs. Control vs. Control Total Volume 41.4:1* 4.5:1* 15.6:1* 2.2:1**(g/Day) Percent 49.6:1* 4.4:1* 13.5:1* 2.4:1** Converted Food Intake(%/Animal/Day) First Bite ∞¹ 7.25:1  4.4:1 3:1  Preference 16/0/0 18/7/115/0/0 18/7/3 Segmentation² *P < 0.02 **P < 0.05 ¹∞ = infinity; No dogsate the Control prototype first so the divisor was zero. ²PreferenceSegmentation = number of dogs preferring Test prototype/number of dogsshowing no preference/number of dogs preferring Control prototype

Example 2—Animal Preference

A chicken by-product meal layered kibble prototype was made by layering,or enrobing, the core of Iams® Mini-Chunks with 10% chicken by-productmeal and 5% chicken broth (20% chicken broth solution), all by weight ofthe kibble. No palatant was added. A 5% coating of fat, by weight of thekibble, was also added. This prototype was compared with Iams®Mini-Chunks and Purina ONE® (Total Nutrition Chicken and Rice) in splitplate, or animal preference, tests. All split plate tests were conductedby standard methods using kenneled dogs. A Salmonella inactivation stepof adding 4% moisture, or water, to the chicken by-product meal layerthen drying the product for three minutes at 260° F. was performed.

The layered prototype was preferred (P<0.05) over Iams® Mini-Chunks (8:1Percent Converted Intake (PCI); See Table 2). The layered prototype wasalso preferred (P<0.05) over Purina ONE® (3:1 PCI).

TABLE 2 Summary Results of Preference Tests Compared to Reference TestsTest (Chicken Test (Chicken by-product meal by-product meal LayeredPrototype) Layered Prototype) Results vs. Iams ® MiniChunks vs. PurinaONE ® Total Volume 7.1:1*  4.9:1** (g/Day) Percent 8.2:1* 3.3:1*Converted Food Intake (%/Animal/Day) First Bite 1.7:1  2.9:1  Preference14/2/0 12/3/1 Segmentation¹ *P < 0.05 **P < 0.10 ¹PreferenceSegmentation = number of dogs preferring Test prototype/number of dogsshowing no preference/number of dogs preferring Control prototype

Example 3—Animal Preference

A chicken by-product meal layered kibble first prototype was made byenrobing a formula re-balanced Iams® Mini-Chunks core kibble with 10%chicken by-product meal and 5% chicken broth (20% chicken brothsolution), all by weight of the kibble, in a 32-liter pilot Bella mixer.A palatant system of 1% chicken liver digest and 2% chicken visceradigest was added as an additional coating to this prototype along with5% fat, by weight of the kibble. In sum, this prototype was reformulatedto have similar nutrient composition as Iams® Mini-Chunks. A secondprototype was made similarly to this one with the exception that it useda different binder, 5% whey protein isolate (20% whey protein isolatesolution), and did not include any chicken viscera digest. Theseprototypes were compared to Purina ONE® (Total Nutrition Chicken & Rice)in preference tests. Another comparison included comparing a thirdprototype, which is the first prototype of 10% chicken by-product meallayering using chicken broth as a binder on an Iams® Mini-Chunksextruded core but not rebalanced, to Iams® Mini-Chunks. Also includedwas this same third prototype without including the chicken by-productmeal and again comparing to Iams® Mini-Chunks. All preference tests weretwo days in length and performed with standard methods using kenneleddogs (n=16). The process of making the prototypes with a layer ofchicken by-product meal included a Salmonella inactivation step ofadding 4% moisture, or water, to the chicken by-product meal layer thendrying the product for three minutes at 260° F.

The chicken by-product meal layered re-balanced Iams® Mini-Chunksprototypes (using broth or whey protein isolate) were substantiallypreferred (P<0.05) over Purina ONE® (17:1 and 16:1 Percent ConvertedIntake (PCI); See Table 3). The chicken by-product meal layeredprototype (not re-balanced) using broth as a binder was also preferred(P<0.05) over Iams® Mini-Chunks (8:1 PCI), whereas broth alone (nochicken by-product meal) did not result in as great of an animalpreference boost (2:1, P<0.10). At least three primary conclusions canbe drawn: 1) 10% chicken by-product meal layering in combination withthe existing animal preference system overwhelmingly beat Purina ONE®,2) the positive impact of 10% chicken by-product meal layering ismaintained as the product is re-balanced for protein (i.e., the level ofprotein is reduced in the core kibble) and 3) the impact of 10% chickenby-product meal layering is independent of the influence of the binderon animal preference.

TABLE 3 Summary Results of Preference Tests Compared to Reference TestsTest 3 Test 1 Test 2 10% Chicken by- product Results 10% Chicken by- 10%Chicken by- product meal Layered Iams ® Test 4 product meal Layered Re-meal Layered Re-Balanced Mini-Chunks (not Iams ® Mini-Chunks BalancedIams ® Mini- Iams ® Mini-Chunks - rebalanced) - broth (not rebalanced) -Chunks - broth binder whey protein isolate binder vs. Iams ® brothbinder only Results vs. Purina ONE ® binder vs. Purina ONE ® Mini-Chunksvs. Iams ® Mini-Chunks Total Volume 16.6:1*  15.1:1*  7.1:1** 2.4.1:1**(g/Day) Percent 16.5:1**  16.2:1** 8.2:1**    2.3:1**** Converted FoodIntake (%/Animal/Day) First Bite ∞¹ 31:1 1.7:1  1.1:1  Preference 16/0/016/0/0 14/2/0 9/4/3 Segmentation² *P < 0.02 **P < 0.05 ***NS (P > 0.10)****P < 0.10 ¹∞ = infinity; No dogs ate the Control prototype first sothe divisor was zero. ²Preference Segmentation = number of dogspreferring Test prototype/number of dogs showing no preference/number ofdogs preferring Control prototype

Example 4—Human Sensory

A human sensory descriptive panel of nine was used to assess aromaattributes of dog food. The dog food was evaluated for aroma using 13descriptive attributes and rated on a 0 to 8 point scale.

FIG. 4 shows the panel's aroma characterization for Iams® Mini-Chunks.As can be seen, Mini-Chunks is reduced in Overall Intensity, Yeast, andDirty Socks aroma character. FIG. 5 shows the chicken by-product mealprotein layering prototype of Example 2 with no additional palatant. Thechicken by-product meal protein layering prototype results in increasedOily/Fatty and Overall Meaty character versus other off the shelf dogkibble foods. FIG. 6 shows chicken by-product meal layering prototypeswith the addition of palatant(s) of Example 3, Tests 1 and 2. Thechicken by-product meal protein layering prototype results in increasedOily/Fatty character but had a similar Overall Meaty character versusother off the shelf dog kibble foods. Chicken character was alsoelevated for the chicken by-product meal layering prototype withadditional palatant.

Example 5—Process

About 6000 g of core kibbles of an extruded and dried mixture of groundcorn, chicken by-product meal, minerals, vitamins, amino acids, fishoil, water, and beet pulp are introduced into a paddle mixer in a hopperlocated above the paddle mixer. The mixer is a model FZM-0.7 Forbergfluidized zone 20-liter mixer manufactured by Eirich Machines, Inc.,Gurnee, Ill., USA. The binder component is composed of about 70 grams ofwhey protein isolate (Fonterra NMZP) mixed with about 300 grams of warm(60° C.) water to make a solution. Once the kibbles have been added tothe mixer, the paddles are rotated to fluidize the kibbles. The paddlesare rotated at about 84 RPM and the Froude number is about 0.95. Thewhey protein solution is pumped to the spray valve over the fluidizedzone in the center of the mixer using Cole-Parmer model 07550-30peristaltic pump using a parallel Masterflex US Easyload II pump head.The whey protein solution is sprayed over the fluidized zone of themixer over a period of about 60 seconds. About 750 grams of chickenby-product meal as a protein component is split into two 375 gramportions, and each portion is added in separate corners down the sidesof the mixer over period of about 60 second simultaneously with the wheyprotein addition. A coated kibble is then formed. The doors at thebottom of the mixer are opened to dump the coated kibbles into a metalreceiver. The coated kibbles are then dried in an air impingement ovenat about 140° C. for about 2 minutes. Visual examination of the kibblesshows that the mixture has been substantially evenly coated over thesurface of the kibbles to form a solid layer. Slicing several of thekibbles in half confirms that the distribution of the coating around thesurface of the individual kibbles is substantially even. During theoperation of the mixer in this example, the Froude number was about0.95, the dimensionless flux was about 0.000262, and the convectivecycle time was about 10 seconds.

Example 6—Process/Salmonella

A 200-liter (7 cu. ft.) double axle fluidizing mixer manufactured byEirich Machines, Inc., model FZM 7 is used in this example. Steam isconnected to two ports on opposite corners of FZM 7 mixer. A hot airblower is connected to the mixer to blow in hot air into the top of themixer. About 60 kg of dry (about 7.5% moisture, or water) pet foodcores, or core pellets, are added to the mixer. In a separate container,about 600 grams of whey protein isolate (Fonterra NMZP) binder is mixedwith about 2400 grams of warm (60° C.) water to make a binder solution.Four containers are each filled with about 1.5 kg of chicken by-productmeal (6 kg chicken by-product meal total) as protein. The chickenby-product meal tests positive for Salmonella. This binder solution istransferred to a pressure canister, and a spray nozzle line is connectedbetween the canister and the spray valve that is centered over thefluidized zone of the mixer. Two spray nozzles, each having a flat sprayprofile with an angle of about 45 degrees, are present. The two nozzlesare positioned over the center of the fluidized zone along the axis ofthe paddles, one about half way between one side wall and the center ofthe mixer, and the second about half way between the center and theopposite side of the mixer. The mixer is preheated with hot air to about60° C. The mixer is started at about 55 RPM. The canister containing thebinder is pressurized to about 30 psi, and binder spray is initiatedinto the mixer. At the same time the four containers each holding about1.5 kg of chicken by-product meal are added to the mixer at fourdifferent points: two containers are added at opposite corners of themixer, and two containers are added at the center of the mixer, onopposite sides. The binder and the chicken by-product meal are added tothe mixer over a period of about 45 seconds. After the completion of theaddition of the binder and the chicken by-product meal, while the mixeris still rotating, hot air (about 200° C.) is then blown into the top ofthe mixer at about 40 CFM. Once the hot air starts blowing into themixer, about 15 psig steam at a rate of about 2 kg/min is injected intothe mixer through two steam nozzles on opposite sides of the mixer forabout one minute. The combination to hot air and steam in the mixerresults in a hot air stream of about 95% relative humidity. At the endof one minute, the steam is stopped but the hot air is continued for anadditional four minutes. During this period, the relative humidityinside the mixer drops, and, as it drops, moisture, or water, is removedfrom the surface of the kibble. At the end of the two minutes of hotair, doors at the bottom of the mixer are opened the kibbles are droppedinto a container. Visual examination of the kibbles shows that themixture has been substantially evenly coated over the surface of thekibbles to form a solid layer. Slicing several of the kibbles in halfconfirms that the distribution of the coating around the surface of theindividual kibbles is substantially even. During the operation of themixer in this example, the Froude number was about 0.95, thedimensionless flux was about 0.000261, and the convective cycle time wasabout eight seconds. These are substantially the same conditions ofFroude number, dimensionless flux, and convective cycle time as forExample 5. Since the finished product was substantially the same in thelarger mixer as in the smaller mixer under the same scale up conditions,the scale up criteria can be considered validated. A test for Salmonellaon the finished coated kibbles is negative.

Example 7A—Vitamin Stability

To demonstrate the improved vitamin retention by way of a coatingapplied using a fluidized mixer, a comparison between the process lossand the loss in storage of coated vitamins versus extruded vitamins canbe analyzed. To compare the process loss, current Iams® Mini-chunks wereextruded with and without vitamins. The product with vitamins wasenrobed with a coating of 5% poultry fat mixed with 1.6% chicken liversdigest and 0.14% vitamin premix. The product without vitamins wasenrobed in a fluidizing mixer with a 5% poultry fat coating and a 1.6%chicken livers digest palatant coating. Samples of all the inputs andoutputs of the process were collected and analyzed for vitamin A andvitamin E.

Based on the mass balance around the fluidizing mixer, the coatingprocess had 8.2% vitamin A loss and 3.3% vitamin E loss. The extruderreduced vitamin A by 36% and reduced vitamin E by 11.2%. See Table 4.

TABLE 4 Process Loss of Vitamin A and E in Coating and ExtrusionNutrient % Loss in Coating % Loss in Extruder Vitamin A 8.2 36.0 VitaminE 3.3 11.2

To compare the loss in storage, vitamin coated products and extrudedvitamin products were bagged and sealed into 13 multi-wall paper bags.The bags were stored in accelerated conditions (100° F. and 50% relativehumidity) and ambient conditions (70° F. and 25% relative humidity). Twomore prototypes were evaluated in the storage stability testingincluding one as Iams® Mini-Chunks with one layer of Paramount B fromLoders Croklaan (partially hydrogenated palm kernel oil) and a secondlayer of vitamins, fat, and palatant, and the second as Iams®Mini-Chunks with 5% chicken broth and 10% chicken byproduct meal mixedwith vitamins as the coating. The two products were sealed and stored inboth accelerated and ambient conditions as above.

The products held in storage were sampled and analyzed for vitamin A andE. The results were normalized because the level at time zero was notconsistent for all the products. FIGS. 7 and 8 show the results. FIG. 7shows the time in weeks on the x-axis and the ratio of the final vitaminamount to the initial vitamin amount on the y-axis. Overall, the vitamincoatings maintained greater vitamin A stability than the extrudedvitamin control. The vitamins in the chicken fat showed a large drop invitamin A levels after the first two weeks but rapidly became stable. Itwas hypothesized and later verified with benchtop testing that thechicken fat does not have the binding capability to adhere the ricehulls in the vitamin premix because the particle size is too large. Thisissue can be resolved using a stronger binder, which is demonstrated bythe improved vitamin A stability using Paramount B and chicken broth asbinders.

Example 7B—Vitamin A Stability

Four additional kibbles were compared. The coated kibbles compared allused a rebalanced Iams® Mini-Chunks core. The four coatings were: 1)beadlet homogenized, which is a kibble coated with a whey proteinisolate solution homogenized with vitamin A crosslinked with a gelatin(the standard crosslinked form of vitamin A from BASF and DSM). Themixture was homogenized with a high sheer mixer to decrease the particlesize of the beadlet in order to better adhere it to the surface of thekibble. 2) Coated beadlet, which is a kibble coated by spraying wheyprotein isolate solution on the kibbles for 10 seconds, then adding thecrosslinked vitamin A dry to the mixer while still spraying the bindersolution over an additional 45 seconds. 3) Powder A, which is a kibblecoated by adding a water soluble form of vitamin A to the whey proteinisolate solution then coating the solution over the kibbles. The powderform is vitamin A in a starch matrix. 4) An extruded kibble with vitaminA mixed with the core prior to extrusion. All of the kibbles usedvitamins that were coated at 0.13% by weight of the formula.

The result of the process loss and storage loss of Vitamin A are shownin Table 5. The storage loss procedure performed was that as describedin Example 7A.

TABLE 5 Process and Storage Loss of Vitamin A % Loss In % Loss in %Total % Total Process Storage Loss Retention Extruded Vitamin A in 37 7260 40 Premix Beadlet Homogen in WPI 28 35 43 57 Beadlet coated with WPI5 49 39 61 Powder A with WPI 11 65 45 55

Example 8—Aroma Analysis

In this Example, 19 studies of different kibble prototypes wereconducted analyzing the aroma of a coated kibble. This method uses SolidPhase MicroExtraction Gas Chromatography/Mass Spectrometry (SPME-GC-MS)to analyze pet food samples for compounds associated with aroma (asdescribed hereinafter). Additionally, the degree of correlation betweenthe SPME data and the animal preference (PREF) was studied to determinewhich formula components correlate to the highest, or best, PREF.

The 39 SPME analytes were grouped into one of 19 aromatic compoundfamilies along with the corresponding correlation with Split Plateanalysis of Ratio Percent Converted Intake and First Bite. The SPMEresults from the current Iams® Mini-Chunks and the first prototype andsecond prototype of Example 3 were then compared to identify analytesthat differed in the lead Test Prototypes. Results indicate that theanalytes 2-Piperidione, 2,3-pentanedione, 2-ethyl-3,5-dimethypyrazine,furfural, sulfurol, and indole were all elevated or representative offamilies with elevated levels compared to current Iams® Mini-Chunks.These compounds also were significantly (P<0.01) correlated (R2>0.60)with improved animal preference response by dogs, as shown in Table 6.

TABLE 6 Aromatic Compounds and Dog Preference Aromatic CompoundCorrelation P-Value 2-Piperidinone 0.72 0.00055342 2,3-pentanedione 0.760.00010555 2-ethyl-3,5-dimethylpyrazine 0.70 0.00052086 Furfural 0.680.00097682 Sulfurol 0.69 0.00082698 Indole 0.62 0.00356432

Example 9 Continuous Fluidizing Paddle Mixer

Brown kibbles are fed continuously into a continuous fluidizing paddlemixer manufactured by Hayes & Stolz (Ft. Worth, Tex., USA) from a feedhopper elevated above the mixer. The mixer is filled to the center lineof the axles with kibbles, and the speed of the paddles is adjusted togive good fluidization of the kibbles and a residence time in the mixerof about 45 seconds. The Froude number is approximately 0.95. The flowrate of kibbles through the mixer is about 40 kg/min. Once steady stateflow is established in the mixer, a 1-liter sample of white-coloredkibbles is added into the entrance of the mixer. In an ideal mixer, thewhite kibbles would go through the mixer in a coherent slug, and theywould all exit the mixer at the same time. In a real mixer the kibblesget bounced around both forward and backward as they move through themixer, so they come out as a distribution around a mean residence time.In order to measure this distribution, approximately 500 gram samples ofwhite kibbles are collected every 5 seconds at the exit of the mixer,starting when the 1-liter sample of white kibbles is added to theentrance of the mixer. The percentage of white kibbles in each sample byweight is measured. Using the mathematical methods outlined inLevenspiel, “Chemical Reaction Engineering,” the residence timedistributions are calculated.

Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Time (t) 0 5 10 15 20 25 30 3540 45 50 55 60 65 after 1 liter of white kibbles is added to theentrance of the mixer (seconds) Mass of 0 0 0 0 0 0 64 873 1159 444 60 91 0 white kibbles in the sample at the exit (grams) Total 3197 3312 33143450 3066 3249 3613 3473 3044 3310 3786 3240 mass of kibbles in thesample at the exit (grams) t* mass 0 0 0 0 0 0 1920 30555 46360 199803000 495 60 0 white kibbles t² * mass 0 0 0 0 0 0 57600 1069425 1854400899100 150000 27225 3600 0 white kibbles${{mean}\mspace{14mu} t} = {\overset{\Sigma tiCi\Delta t}{\underset{\Sigma Ci\Delta t}{=}}{39.22222\mspace{14mu} \sec}}$${\sigma 2} = {\overset{{{\Sigma ti2Ci\Delta t}({{mean}\mspace{14mu} t})}2}{\underset{\Sigma Ci\Delta t}{=}}{17.69008\mspace{14mu} \sec \; 2}}$Dimensionless σ2 = 0.011499 Dimensionless σ2 = 2 (D/uL)-2 (D/uL)2(1-e-(uL/D)) D/uL = 0.005775 Peclet # = 173.1585 Flowrate = 40.20764kg/min

A Peclet number greater than about 6 is considered approximately plugflow. A Peclet number above about 100 is considered good plug flow.

Example 10

This example relates to reducing the surface energy using an emulsifier,which can result in better adhesion of the coating to the surface of thekibble. Two preparations for a Probiotic powder, including itsconstituents, are made. Both powders are identical except that Powder Acontains probiotic and 0.1% polysorbate 80, and powder B containsprobiotic and 0.5% polysorbate 80. The surface energies of the powdersare measured and are shown in the table below. Both powders have beenscreened so that all particles are less than about 75 microns.

Interfacial tension between Surface Energy (mJ/m²) the coating and thekibble Sample Non-Polar Polar (dynes/cm) Powder A 33.88 8.127 5.4 PowderB 34.63 1.443 0.7

About 5000 grams of uncoated kibbles that have been pre-sieved to removeany fines or powders are added to a 20-liter Forberg® fluidizing mixer.The mixer is turned on, the paddles are rotated at about 87 RPM, and theFroude number is about 1. About 5 grams of Powder A are added to the topof the mixer over the fluidized zone over a period of about 30 seconds.The product is removed from the mixer, and collected in a plastic bag.The product is then analyzed for Probiotic activity.

About 5000 grams of uncoated kibbles that have been pre-sieved to removeany fines or powders are added to a 20-liter Forberg® fluidizing mixer.The mixer is turned on, the paddles are rotated at about 87 RPM, and theFroude number is about 1. About 5 grams of Powder B are added to the topof the mixer over the fluidized zone over a period of about 30 seconds.The product is removed from the mixer, and collected in a plastic bag.The product is then analyzed for Probiotic activity.

The results of these analyses are shown in the table below. The lastcolumn represents the percent log retention of the Probiotic, meaningthe log of the Probiotic activity of the coated kibble dividing by thelog of the Probiotic activity of the powder added to the mixer (beforeaddition to the kibble).

Interfacial Total Total % log retention tension Probiotic probioticProbiotic between the activity of the activity added to the coating andpowder added of the mixer that the kibble to the mixer coated kibbleadhered to Material (dynes/cm) (CFU/gram) (CFU/gram) the kibbles PowderA 5.4 6.49E+08 2.23E+07 83.4% Powder B 0.7 2.13E+08 1.16E+08 96.8%

This example shows that lowering surface energy of the powder willresult in better adherance of the powder to the kibble.

Example 11

This example shows how reducing the surface energy using an emulsifiercan result in better adhesion of the coating to the surface of thekibble. About 30 kg of uncoated kibbles are pre-sieved to remove anyfines or powders. A 20-liter Forberg® fluidizing mixer is equipped withan air-actuated spray nozzle, a peristaltic pump to feed the nozzle, anda large container of hot chicken fat. For each experiment about 7300 gof unenrobed kibble and 990 g protein (chicken meal) coating powder areweighed out. The protein coating powder has an average particle size ofabout 140 microns. These dry ingredients are added to the mixer. Thepump rate is set so that 330 g of fat will be sprayed in over 60seconds. The mixer is started, the paddles are rotated at about 87 RPM,and the Froude number is about 1. After about 10 seconds, the pump isturned on and the required amount of fat is sprayed into the mixer overthe kibbles for about 60 seconds. The product is removed from the mixerand sieved to separate the kibbles from the coating that did not adhereto the surface of the kibbles. Three experiments were conducted. Thefirst experiment used the fat as a binder for the protein powder. Thesecond experiment was the same as the first except that about 8 grams ofPolysorbate 80 was added to the fat prior to spraying it on the kibbles.The third experiment was the same as the first except that about 12grams of Polysorbate 80 was added to the fat prior to spraying it on thekibbles. The results of the experiments are shown in the table below.These results show that a small amount of Polysorbate 80 added to thechicken fat reduces the amount of protein coating that does not adhereto the kibbles.

Grams of Grams of coating Percent of coating PS 80 added % PS 80 thatdid not stick that did not stick to the fat in fat to the kibbles to thekibbles Exp 1 0 0.0% 47.24 4.8% Exp 2 8 2.4% 27.05 2.7% Exp 3 12 3.6%18.22 1.8%

Decreasing Palatant Levels

The process above can be followed for the making of a pet food. In oneembodiment, a core pellet as described herein can be provided along withat least one coating material, also as described herein. The coatingmaterial can be coated onto the core pellet to form a coated kibble.Such coating can be performed by way of a continuous mixing process. Insuch a continuous process, certain process parameters can be controlledand/or modified to apply the coating material to the core pellet. For afluidizing mixer these process parameters include paddle length, paddleangle, number of paddles, rotation speed of the paddles, level of fillof the mixer, distance of the paddle tip from the wall and/or the bottomof the mixer, mixing time for a batch mixer, flow rate through the mixerfor a continuous mixer, location of the addition points of the liquidcoating, location of the addition points of the solid coating, order orsequence of the coating addition, pattern of spray of the nozzle for theliquid coating, droplet size of the liquid coating, and particle size ofthe solid.

Such controlling and modification of process parameters can result inchanges to process measurements such as the Froude number, Pecletnumber, acceleration number, among others.

In another embodiment, the continuous paddle mixer (CPM) as describedcan be used to coat palatant onto pet food cores to produce a coatedkibble. It has been found that less palatant can be used when using aCPM coating process to coat the palatant onto the pet food core, andless palatant can actually produce similar benefits as that of a coatedpet food kibble having higher amounts of palatant in the coating thatwas coated onto the core by typical coating processes, such as APECcoating process. Typical coating processes are described in U.S. Pat.No. 7,479,294.

For example, an APEC coating process generally uses a tower section anda blender section. The tower section is in front of and above theblender section. Dry kibbles from a feeder land on a low RPM spinningdisk at the top of the tower. The kibbles are spun into a 360 degreecurtain that fall through the tower. Inside the curtain of fallingkibbles is one or more rapidly spinning disks. The liquid or slurry,such as a coating of fat and/or palatant, to be coated on the kibbles isfed to the center of the rapidly spinning disks. The centrifugal forceof the rotating spinning disk(s) sends the liquid or slurry outward fromthe disk toward the falling kibbles, partially coating a portion of thekibbles. The kibbles then fall into the blender section. The blenderconsists of a dual axle ribbon blender or a dual axle paddle blender.The axles may be co-rotating or counter rotating. Counter rotating axlesmay be directed so that the rotation is upward from the center anddownward along the sides, or downward from the center and upward alongthe sides. The RPM of the axles is adjusted so that all of the kibblesremain in a packed bed in the body of the mixer. The kibbles usually arenot fluidized. Coating is spread among the kibbles by kibble-to-kibblecontact in the kibble bed, producing a coated kibble.

With a CPM coating process, a continuous stream of kibbles can be sentthrough a fluidizing mixer in a continuous process. The fluidizing mixercan be a counter-rotating dual-axis paddle mixer. The rotation of theaxles can be such that the kibbles in the mixer are moved upward fromthe center of the mixer and downward along the sides. The RPM of theaxles can be adjusted so that the kibbles in the center of mixer abovethe level of the axles are fluidized, i.e., moving independently upwardwith little or no contact with other kibbles in that section of themixer. While the kibbles are moving upward in the air in the fluidizedsection, they tend to be rotating in random directions. Coatings, suchas fat, palatants, liquid coating, slurry coating, solid powder coating,or some combination of these can be applied to the kibbles in thefluidized zone. Each kibble in the bed can be fluidized through thecoating zone at least once during its travel through the mixer. Acontinuous fluidized bed mixer can be made using a dual axle paddlemixer obtained from Hayes & Stolz, Fort Worth, Tex. The angle of thepaddles can be adjusted so that the Froude number is about 1 and thePeclet number is about 40.

Thus, it has been found that using a CPM to coat palatant onto a petfood core can result in using less palatant while also providing similarbenefits. Thus, typical coating processes, such as the APEC coatingprocess, apply levels of palatant that are more than the levels used bya CPM. However, as described above, the CPM coating process used to coatpalatant onto pet food cores can actually deliver similar, or evenbetter, benefits than the typical coating processes.

Thus, the present inventors have determined that by using a CPM coatingprocess, the levels or amounts of coating components, such as palatants,can be decreased and still provide a similar benefit as if the coatingcomponent was applied at a higher level.

Without being bound by theory, it is thought that potentially fourreasons exist why using less palatant by way of a CPM coating processcan deliver similar benefits as a kibble coated by way of an APECcoating process. First, it is theorized that the CPM coating processimproves the distribution of palatant onto the kibble core. Second, itis theorized that the CPM coating process delivers greater adherence ofthe palatant onto the kibble core. Third, it is theorized that the CPMcoating process avoids or decreases the shearing of the palatant sincethe palatant is not exposed to typical mixing processes that aretypically used to coat the palatant onto the core. Fourth, it istheorized that when the other coating process are used such that fat andpalatant are mixed together prior to coating on the kibble core, thatresulting mixture of fat and palatant entraps aromatics provided by thepalatant. A CPM coating process that coats the fat onto the corefollowing by coating of the palatant thus results in little to noentrapment of the aromatics provided by the palatant.

In one example, Eukanuba® Premium Performance was used as a kibble coreand was enrobed with a coating in three different samples. The coatingcomprises fat and palatant. The amount of palatant was varied as followsfor the three samples. One control and two test samples were produced.The coating was enrobed into the kibble core and in all samplescomprised palatant as described below and poultry fat at 8.1% by weightof the coated kibble. The coating also comprised a palatant. Thepalatant was spray dried hydrolyzed chicken. For the control sample, theAPEC process was used to enrobe the coating comprising 1%, by weight ofthe coated kibble, palatant onto the kibble core. For the first testsample, the CPM coating process was used to enrobe the coatingcomprising 0.8%, by weight of the coated kibble, palatant onto thekibble core. For the second test sample, the CPM coating process wasused to enrobe the coating comprising 0.7%, by weight of the coatedkibble, palatant onto the kibble core. Standard split plate tests (asdescribed herein), two days in length with 16 dogs, were conducted toevaluate food preference. Product aroma was assessed by a humandescriptive attribute panel (described as Aroma Test Human Sensoryherein). Analytical oxidation values were also measured. The results ofthese tests are shown in Tables A through F.

Analytical oxidation values for the CPM made products were all inacceptable ranges compared to APEC control (Table A). Split plateresults indicate that 0.8% palatant coated by CPM was preferred over thecontrol (1% APEC) process with a higher amount of palatant (Tables B andC). Split plate results also indicate that 0.7% CPM coated producttended (P=0.07) to be preferred over 1% APEC coated product (Tables Dand E). Human sensory results indicate few significant aroma differencesbetween products (Table 6). However, a trend (P=0.19) existed forincreasing overall meaty aroma detected in the 0.7 and 0.8% CPM productscompared to the 1% APEC coated products. Given that dogs have up to 100times more olfactory sensitivity than humans, it is plausible thatsubtle aroma differences detected by humans are magnified by the dog'spowerful sense of smell.

TABLE A Analytical Oxidative Stability Results Human OxidationEvaluation (1 = fresh, 2 = acceptable, 3 = Oxygen Bomb Sample ID TotalAldehydes rancid) (h)   1% APEC 25 1.14 6 0.8% CPM 31 1.43 5 0.7% CPM 321.43 4

TABLE B 0.8% Palatant Coated with CPM was preferred over 1.0% PalatantCoated with APEC Control Product Total Percent Volume Total ConvertedPercent Intake Volume Intake Median Converted WorkID Diet Median (g)p-value (%) p-value Control: 1% APEC 40.5 0.0075 15.0 0.0075 Test: 0.8%CPM 150.0 85.0

TABLE C 0.8% Palatant Coated with CPM Resulted in a Greater Number ofFirst Bite Incidences than 1.0% Palatant Coated with APEC ControlProduct Total Included Control: Test: Date Total Study N in Analysis N1% APEC 0.8% CPM 1 15 15 3 12 2 15 15 3 12

TABLE D 0.7% Palatant Coated with CPM tended to be preferred over 1.0%Palatant Coated with APEC Control Product Total Percent Volume TotalConverted Percent Intake Volume Intake Median Converted Diet Median (g)p-value (%) p-value Control: 1% APEC 73.5 0.0707 40.0 0.0707 Test: 0.8%CPM 130.5 60.0

TABLE E 0.7% Palatant Coated with CPM Resulted in a Greater Number ofFirst Bite Incidences than 1.0% Palatant Coated with APEC ControlProduct Total Included Control: Test: Date Total Study N in Analysis N1% APEC 0.7% CPM 1 15 15 4 11 2 15 15 3 12

TABLE F Aroma Results CPM Overall APEC 1% CPM 0.7% 0.8% CPM 1% p-valueOverall 28.1 27.9 27.1 28.8 0.9074 Intensity Oily/Fatty 18.9 19.4 19.219.8 0.5406 Aroma Overall Meaty 7.5 8.9 8.7 8.2 0.1881 Aroma ChickenAroma 4.2 4.9 4.1 3.3 0.1944 Fish Aroma 4.7 5.2 4.6 4.5 0.9209 Yeast 5.66.2 5.6 5.9 0.6099 Toast 8.5 7.3 8.2 8.0 0.8643 Sweet 12.6 12.9 13.110.8 0.3668 Dirty Socks 4.1 3.8 4.3 4.5 0.4836 Cardboard 5.0 5.2 5.1 6.10.3027 Earthy 8.8 8.5 9.4 9.4 0.8456 Grainy 22.9 22.1 21.8 22.0 0.6513Beefy 4.8 5.1 4.4 4.7 0.8421 Sour 4.5 4.5 4.7 4.9 0.9216 Rancid 3.9 4.15.5 4.3 0.0752

Thus, as the results in the tables show, a trend in overall meaty aromaand an increase in split plate preference exist even though lesspalatant was used in the CPM coated test samples when compared with theAPEC coated control sample.

Thus, in one embodiment, a CPM coating process is disclosed forproducing a pet food in the form of a coated kibble. Another embodimentrelates to a pet food in the form of a coated kibble, wherein the coatedkibble comprises a core and at least one coating. The core can be anycore as described herein. The coating can be any coating as describedherein. Additionally, the coating can include a palatant, as describedherein, which can be applied using a continuous paddle mixer (CPM). Inone embodiment, application of the palatant by way of the CPM can resultcoated kibbles providing similar benefits to those of palatant coatedkibbles having more palatant applied. In one embodiment, the palatantcan be coated using a CPM at about 0.8%, by weight of the kibble, andhave similar or better preference and aroma properties of a 1.0%, byweight of the kibble, non-CPM coated kibble, such as an APEC coatedkibble. Palatant coatings can be applied using the CPM coating processat any level as disclosed herein. However, it is theorized that acoating of palatant using the CPM coating process will have thebeneficial affects similar to a much higher coating of palatant that isapplied by a non-CPM coating process, such as an APEC coating process.It is additionally theorized that the CPM coating process improves thedistribution of palatant onto the kibble core, delivers greateradherence of the palatant onto the kibble core, and allows for adecrease or complete avoidance of shearing of the core matrix and thepalatant that typically occurs with coating processes since the palatantand core are not exposed to the APEC coating process when the CPM isused to coat the palatant.

The palatant used herein can be a moist, or liquid, palatant or a drypalatant. Generally, moist palatants can have a moisture content ofabout 12% or greater, and dry palatants can have a moisture content ofless than about 12%. In other embodiments, the palatant can be acombination of moist and dry palatants. In other embodiments, the moistand dry palatants can be added in any order or can be mixed together.For example, a wet palatant can be applied first followed by the drypalatant. In another embodiment, the dry palatant can be applied firstfollowed by the moist palatant. Any order and combination is envisioned,and any number of palatants, either moist or dry, can be used.

As described herein, with the CPM coating process, the core kibble canbe coated with a coating. The coating can comprise a fat and a palatant.The coating can be a mixture of the fat and palatant, which is thencoated onto the core kibble. The coating can be comprised of separateadditions of fat and palatant to the core kibble. For example, the corekibble can be first coated with a fat and then can be coated with apalatant. Thus, a two step coating can be envisioned, one step being thecoating of the fat, the second step being the coating of the palatant.

In one embodiment, the coating comprising a fat and palatant can becoated using a CPM. The palatant can be present at about 0.8%, by weightof the kibble, and have similar or better than preference and aromaproperties of a 1.0%, by weight of the kibble, non-CPM coated kibble,such as an APEC coated kibble. In another embodiment, the palatant canbe present at about 0.7%, by weight of the kibble, and have similar orbetter than preference and aroma properties of a 1.0%, by weight of thekibble, non-CPM coated kibble, such as an APEC coated kibble.

Thus, in one embodiment, a process of making a pet food is disclosed.The process comprises forming a core mixture comprising a starch source,a protein source, and a fat source; extruding the core mixture to form acore pellet wherein the starch is gelatinized during extrusion;providing a fat coating and a palatant coating; applying the fat coatingto the core pellet to form a fat coated core pellet; applying thepalatant coating to the fat coated core pellet after applying the fatcoating to form a coated kibble comprising less than 12% moisture;wherein the fat coating and the palatant coating is applied using acontinuous paddle mixer process.

Methods Salmonella Detection

Detecting whether Salmonella has been sufficiently deactivated can beperformed by many methods. In one exemplary embodiment, a BAX System PCRassay is used with automated detection, and the following steps areperformed.

The sample is prepared by weighing 25 grams of the sample to be testedinto a sterile container. 225 ml of sterile buffered peptone water (BPW)are added to the sample. The sample is incubated at 35-37° C. for atleast 16 hours. Next, a 1:50 dilution is prepared by transferring 10 μlof the sample to a cluster tube containing 500 μl of Brain HeartInfusion (BHI). The tube is incubated at 35-37° C. for three hours.Heating blocks are warmed and the sample prep order is recorded manuallyas well as into the BAX system Kit Lot Number. Sample IDs are enteredinto the BAX System's software, following instructions in user guide.The thermocycler is initiated and after the three-hour incubation periodin BHI, 5 μl of the re-grown samples is transferred to cluster tubescontaining 200 μl of lysis reagent (150 μl into 12 ml lysis buffer).These tubes are heated 20 minutes at 37° C., then 10 minutes at 95° C.The tubes are then cooled 5 minutes in lysate cooling block assembly. 50μl of lysate is transferred to corresponding PCR tubes and the tubescapped with flat optical caps in order to detect fluorescent signal. Theentire cooling block is taken to the thermocycler/detector and the PCRtubes are loaded into the heating block (making sure the tubes areseated in the wells securely). The thermocycler amplifies DNA,generating a fluorescent signal, which is automatically analyzed todetermine results.

When the thermocycler/detector is complete, the screen displays a windowwith a modified rack view, showing different colors in the wells, with asymbol in the center to illustrate the results. Green (−) symbolizes anegative for target organism (Salmonella), a red (+) symbolizes apositive for target organism (Salmonella), and a Yellow with a (?)symbolizes an indeterminate result. The graphs for negative results arereviewed to check for the large control peak around 75-80. The graphsfor positive results are interpreted using Qualicon's basis forinterpretation. If a Yellow (?) result arises, the (?) sample lysate isretested as well as a BHI sample lysate.

Split Plate Test

This protocol describes the methodology and standard operating procedurefor conduction of normal canine split plate testing, including ratiopercent converted intake and ratio first bite.

All diets fed must receive a “negative” result for Salmonella asdescribed in the Salmonella method section herein. Once diets havepassed microbial testing successfully, the testing can begin. Diets forsplit plate tests are kept in Rubbermaid® brand storage bins that arelabeled with the corresponding color coded label for each diet. Splitplate test food bowls are filled the day before the test begins and thenstored overnight in the corresponding Rubbermaid® brand diet bin. Ifthey cannot fit in the bin with the diet, they are placed in anadditional bin that has also been properly labeled with the correctcolor/patterned label. Split plate tests are fed at the beginning of theday, such as at 7:00 am.

The food carts are loaded each morning with the bowls being placed inkennel chronological order. Upon entering the kennel area, thetechnician picks up any feces from during the night and completes avisual check of each animal. After this initial animal check of the day,feeding begins. A clipboard containing the working copy, the attributesheet, and any other essential information, has previously been placedon the cart. First choice information is then collected. The technicianopens the kennel door, bowls in hand, and encourages the dog to aneutral, or centered, position. The bowls are held in front of the dogbriefly, to ensure use of olfactory sense, and then placed in the bowlrings. The door is closed quietly, and the technician steps back andwaits until the animal makes the first choice. The choice is noted witha circle on the sheet, and the technician progresses through the kennel,repeating the above actions for every panel member.

The bowls remain with the animals for one hour, or until either one bowlis completely consumed, or 50% of each bowl is consumed. The bowls arecollected, returned to the kitchen, and weighed. The amount remaining,or “ORTs”, is recorded in the correct diet column by each individualpanel members' name. After being weighed, the bowls are placed in thewasher rack and mechanically processed to ensure effective sanitation.

Any aberrant behavior is recorded. Any out of the ordinary events suchas renovations, special collections, healthcare surveillanceblood-draws, etc., are also recorded there. Any of these are immediatelybrought to the attention of the viewer. If any animals are ill, exhibitloose stools, vomiting, or need intercession, notification is done.

Generally, diet one is the test diet; diet two is the control diet.ORTs, as mentioned above, means the amount of food left after thefeeding is completed.

Typical split plate data that is recorded can include ratio percentconverted intake and ratio first bite. As used herein, ratio percentconverted intake is the ratio of the food consumed of diet one versusdiet two. For example, if dogs are fed diet one and diet two, and 60grams of diet one is consumed while 40 grams of diet two is consumed,the ratio percent converted intake would be 60 g:40 g, or 1.5:1. As usedherein, the ratio first bite is the ratio of the first food that ananimal takes a bite of. For example, if ten dogs are presented with dietone and diet two, and seven dogs take a first bite of diet one, andthree dogs take a first bite of diet two, then the ratio first bite is7:3, or 2.33:1.

Aroma Test Human Sensory

This protocol describes the methodology for sensory evaluation to beused by sensory scientists. The method employs the human nose ofpanelists (human instruments) to evaluate aroma. First, an Odor SensoryAcuity test is administered to potential panelists for qualification asa panelist. The Odor Sensory Acuity test comprises two parts. The firstpart is odor identification. Ten samples are provided to a potentialpanelist. The potential panelist sniffs the samples and then identifieseach aroma of the samples from a list of aromas given to him/her. Thesecond part is the same/different test. Ten pairs of samples arepresented to the potential panelist. The potential panelist sniffs eachpair of samples and determines if they are the same aroma or a differentaroma. Different aromas can include different by character, for example,caramel versus cherry, and different by intensity, for example, lowpeppermint concentration versus high peppermint concentration. Apanelist is deemed a qualified panelist if they achieve 75% or greaterin correct identifications of the two parts of this Odor Sensory Acuitytest, cumulative.

The qualified panelists based on the Odor Sensory Acuity test are thenutilized for descriptive analysis of diet aroma, using ingredients,reference standards, and finished product samples. Panelists rateproducts for various attributes using a 0 to 8 point scale, as follows.

Samples are prepared by placing 90-100 grams of each test product(coated kibbles) in glass jars with Teflon lids for sample evaluations.Panelists then sample one sample at a time and evaluate all samples in aset. Evaluation by the panelist comprises the following:

1) Panelist unscrews the lid from its jar;

2) Panelist takes three deep quick sniffs and then removes the samplefrom the nose.

3) Panelist makes assessment using a 0 to 8 point scale and recordsassessment.

4) Panelist breathes clean air for at least 20 seconds between samples.

Assessments by the panelists are performed according to the followingsensory attribute aroma definitions. Additionally, the following aromareferences are given to aid the panelist in assessing the sample on the0 to 8 point scale.

Sensory Attribute Aroma Definitions:

Oily/Fatty: Intensity of oily; includes greasy, cooking oil, peanut oil,olive oil and fatty (poultry fat).

Chicken: Intensity of chicken aroma: includes chicken by-product meal,chicken soup, roasted chicken.

Fish: Intensity of fish aroma; includes fish meal, wet cat food (oceanfish and tuna), fish oil.

Yeast: Intensity of yeast aroma-more specifically brewer's yeast.

Toasted: Intensity of toasted aroma; includes roasted nuts or coffee andnutty, lightly toasted to more toasted.

Sweet: Intensity of sweet aroma; includes candy, caramel-like, toffeelike, butterscotch, “sugar babies”, floral.

Dirty Socks: Intensity of Dirty socks smell—includes musty.

Cardboard: Intensity of cardboard or corrugated paper.

Earthy: Intensity of earth/fresh dirt like aroma.

Grainy: Intensity of grain like, oats, cereal smell or corn.

Beefy: Intensity of beef smell-includes JAMS® brand wet, savory saucebeef, and JAMS® brand dog chunks (beef).

Overall Intensity: Intensity of overall aroma of any kind, ranging frommild, faint, light or weak, to strong, heavy, or pungent.

Aroma References:

Oily/Fatty Chicken Vegetable Oil - 1 Diluted chicken broth - 2.5 OliveOil - 7 Chicken Broth - 4 Chicken Stock - 6

Meaty Fish IAMS ® Ground Dog Beef/Rice - 1 IAMS ® Original Chicken - 1IAMS ® Beef Stew - 4 IAMS ® Original Fish - 2 Tuna - 8

Yeast Toasted Dry yeast - 1 Toast - 1 Wet yeast - 8 Espresso groundcoffee - 6 Burnt toast - 7

Sweet Dirty Socks Karo ® syrup - 2 Musty Rag - 7 Sugar Babies - 7.5

Cardboard Earthy Paper from dog/cat food bag - 1 Dirt - 7 Corrugatedcardboard - 2 Wet corrugated cardboard - 6

Grainy aroma Beefy IAMS ® ground Savory Dinner w/meaty beef Diluted beefbroth - 1 and rice - 1 Dried beef - 2 IAMS ® Original chicken - 3 Beefbroth - 7 Roast beef - 7-8

Overall Intensity Pedigree ® Chunks (wet) - 2 Purina ® Mighty Dog ®(wet) - 3 Beneful ® Original Dry - 7

Aroma Analysis

This method uses Solid Phase MicroExtraction Gas Chromatography/MassSpectrometry (SPME-GC-MS) to analyze pet food samples for compoundsassociated with aroma of the pet food. The following procedure was usedto analyze the headspace volatiles above a pet food sample. The kibbleproduct was weighed to 2.0 g (+/−0.05 g) into a SPME headspace vial (22mL with septum cap) and the vial capped. Duplicates of each sample to beanalyzed were prepared. The samples were placed into an autosampler trayof a Gerstel MPS 2 autosampler (Gerstel, Inc. Linthicom, Md., USA). Thesamples are heated to 75° C. for 10 minutes (equilibration time) andthen sampled with a 2 cm Carb/DVB/PDMS SPME fiber (Supelco, Bellefonte,Pa., USA) at 75° C. for 10 min. The SPME fiber is then desorbed into theGC inlet (250° C.) of an Agilent 6890GC-5973 MS for 8 min. The GC isequipped with a Restek Stabilwax column 30 m×0.25 mm×0.25 m film. The GCtemperature is initially 50° C. and held at this temperature for 1minute, then ramped at 15° C./min to 240° C. and held for 4 minutes. Thechromatogram is measured against standard retention times/target ionsusing Chemstation software, with the peaks corresponding to specificcompounds collected using extracted ion chromatograms (EIC). The areaunder the curve was then measured to give a SPME analysis number orcount.

A statistical pair-wise correlation was made between the aromaticcompounds and two outcome variables from the preference test (RatioPercent Converted Intake and First Bite). Then the headspace aromaticcompounds of Iams® Mini-Chunks, and the first prototype and secondprototype of Example 3 were compared. Those aromatic compounds thatwere 1) significantly correlated with preference and 2) elevatedcompared to Mini-Chunks were identified as most likely responsible forimproved dog preference.

Vitamin Amounts

The following supplies are used:

Supplies Part Number Vendor Retinol 95144 Fluka Reagent Alcohol 9401-02VWR Potassium Hydroxide (45%) 3143-01 VWR Ethoxyquin IC15796380 VWRα-Tocopherol 95240 Fluka Glacial Acetic Acid 9511-02*BC VWR 4.6 × 100 mmOnyx OOF-4097-EO Phenomenex L-Ascorbic Acid A-7506 Sigma Acetonitrile,Optima grade A996-4 Fisher Scientific BHT, ≧99.0% B 1378-100GSigma-Aldrich

Using top-loading balance, weigh 70.0X g (where X is any number) of thesample into a 250 ml glass jar with a screw-on lid with Teflon® lining.Add 140.0X g of deionized water, screw the lid onto the container, andmix the content well. Place container into a water bath for 2 hours at50° C. Remove container from the water bath.

Using Retsch Grindomix GM 200 Knife Mill, pulverize the content of theglass jar in two steps of 25 seconds at 10000 rpm. Collect 100-150 ginto a plastic sample cup for further analysis.

Using analytical balance, weigh between 3 and 3.3 g of the resulted mixinto a 20 ml amber vial recording the weight to nearest 4 decimalplaces. Add 0.25-0.3 g ascorbic acid. Place magnetic bar inside thevial. Add 10 ml of reagent alcohol, and then 5 ml of 45% w/w potassiumhydroxide solution. Cap the vial and vortex the content. Record theweight of the vial and place it on the hot block with magnetic stirrer.Keep the sample on the hot block for 1 hour at 110° C. Remove the vialand place it in a refrigerator to cool to or below room temperature.Record the weight of the vial after saponification. Difference betweeninitial and final weights should be within 2% or sample must beredigested.

Place autosampler vials into a rack, and add 0.5 mL of 60:40 ReagentAlcohol:Acetic Acid with ˜100 ppm of Ethoxyquin. Place into the freezerfor at least 30 minutes. In the hood, uncap the vials, remove 0.5 mL ofthe saponificated sample, and place it into the chilled autosamplervials. Cap autosampler vials and shake vigorously. Place onto HPLC,which will give concentration of vitamin in extract, μg/mL. The VitaminA peak should be found at close to 5 minutes, and the Vitamin E peakshould be found at close to 12 minutes.

Create standards as follows:

Retinol stock standard: Into a 250 mL actinic volumetric flask, weighabout 200 mg BHT and 100 mg of Retinol, record value to 4 places. Diluteto the line in methanol and mix.

α-Tocopherol stock standard: Into a 250 mL actinic volumetric flask,weigh about 200 mg BHT and 100 mg of α-Tocopherol, record value to 4places. Add about 200 mL of methanol, and shake, making sure all thetocopherol has dissolved. Dilute to the line and mix.

Calculate the concentration of each standard in μg/mL, and place inrefrigerator. When protected from light, these stock solutions can bekept for 2 months.

Standard 1: Into a 10 mL volumetric, add 100 μL of retinol stockstandard and 1 mL of α-tocopherol stock standard. Dilute to the linewith methanol.

Standard 2: Into a 10 mL volumetric, add 1 mL of the Standard 1. Diluteto the line with methanol and mix.

Standard 3: Into a 10 mL volumetric, add 1 mL of the Standard 2. Diluteto the line with methanol and mix.

Run a calibration curve for new column or more frequently if needed. Runa control sample at least once daily at the beginning of the batch.

HPLC Conditions: Column Heater: 30° C.; Injection Volume: 50 μL

Solvent Gradient:

Time % Water % Acetonitrile Flow (ml/min) Max. Press. 0 35 65 0.5 2000.01 35 65 2.5 200 7 30 70 2.5 200 9 0 100 2.5 200 13 0 100 2.5 200 1435 65 2.5 200 14.01 35 65 0.5 200

Column: 4.6×100 mm Onyx Monolithic C18.

Guard column: 4.6×5 mm Onyx Monolithic C18.

Detection: UV/Vis Diode Array or equivalent, at 324 nm and 290 nm.Retention: The Vitamin A peak should be found at close to 5 minutes, andthe Vitamin E peak should be found at close to 12 minutes.Calibration and HPLC Operation. Calibration should be done for each newcolumn with fresh standards. Validity of a calibration curve is checkedwith control samples.Vitamins results are reported in units of IU/kg as follows:

${{{Vitamin}\mspace{14mu} A} = \frac{C*V*{DF}*100}{W*0.3}};$${{{Vitamin}\mspace{14mu} E} = \frac{C*V*{DF}*1.1}{W}};$

whereC—concentration of vitamin in extract, μg/mL (from the HPLC)V—total volume of extraction solvents (reagent alcohol and potassiumhydroxide), mL DF—dilution factor (compensates addition ofneutralization solution)W—sample aliquot weight, g

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1-5. (canceled)
 6. A process, comprising: introducing core pellets intoa continuous fluidizing mixer that includes a first end, a second end,two counter-rotating axes, and paddles that extend from and are orientedat an angle relative to each of the counter-rotating axes; rotating thetwo counter-rotating axes such that the mixer has a Froude number ofabout 0.5 to about 3.0 and a Peclet number greater than about 6;applying a first coating to the core pellets in the mixer to form coatedcore pellets; and discharging the coated core pellets from the secondend of the mixer.
 7. The process of claim 6, wherein, during therotating step, the paddles are configured to move the core pellets fromthe first end toward the second end of the mixer
 8. The process of claim6, wherein the pore pellets have a residence time of about 10 seconds toabout 600 seconds in the mixer.
 9. The process of claim 6, furthercomprising, prior to the discharging step, a step of applying a secondcoating to the coated core pellets.
 10. The process of claim 6, whereinthe first coating includes a component selected from Probiotic,mannoheptulose, an emulsifier, and combinations thereof.
 11. The processof claim 6, further comprising, after the discharging step, a step ofintroducing the coated core pellets into a second mixer.
 12. The processof claim 12, further comprising applying a second coating to the coatedcore pellets within the second mixer.